# Boeing Alert Service Bulletin 737-53A1343: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-8848; AD 2017-10-21 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 737-53A1343](https://openairdocs.org/service-documents/boeing/737-53a1343.md) - Title as filed: SB-737-53A1343-00--BOEING - Pages: 236 - PDF: https://openairdocs.org/files/sha256/21/37/21373c8feb9b14c6cf192e8e39c2323096d31a28b6835045751009e4c9625c76 - Page: https://openairdocs.org/service-documents/boeing/737-53a1343/file/21373c8feb9b ## 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: 737-53A1343 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 Unpublished Work.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March 25, 2016 737-53A1343 1 of 236 4.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 ALERTALERT BLANK PAGE ### Page 3 Table of Contents S u m m a r y ...................................................... 7 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 ALERTALERT ### Page 4 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 ALERTALERT ### Page 5 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 ALERTALERT ### Page 6 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 ALERTALERT BLANK PAGE ### Page 7 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 ### Page 8 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 Air- plane 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 ALERTALERT ### Page 9 (OCR) BOEING SERVICE BULLETIN 737-53A1343 ALERT ALERT 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 ### Page 10 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 ALERTALERT BLANK PAGE ### Page 11 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 ### Page 12 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 ALERTALERT ### Page 13 GroupVariable Number 2PR091 - PR092 2PR096 2PR101 2PR121 - PR122 2PR131 - PR132 2PR141 - PR143 2PR161 - PR172 2PR181 1PS617 - PS625 2PS626 - PS630 1PS704 - PS706 5PS763 - PS799 1PS811 1PS836 - PS837 1PS841 - PS845 2PS846 1PS851 - PS852 1PS856 1PS861 2PS862 - PS863 1PS866 - PS868 2PS871 - PS874 2PS896 - PS897 5PS901 - PS941 2PS956 - PS957 2PS961 - PS963 2PS971 - PS978 4PT012 - PT015 4PT029 - PT031 4PT064 4PT126 - PT138 4PT188 4PT307 - PT309 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 13 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 14 GroupVariable Number 4PT513 - PT517 4PT585 - PT586 4PT643 - PT644 4PT656 4PT681 - PT685 4PT716 - PT717 4PT721 - PT725 4PT801 - PT834 4PT851 - PT854 4PT871 - PT886 4PT901 - PT930 4PT971 - PT973 4PT981 - PT985 4PT996 4PU301 4PU311 - PU313 3PV204 - PV209 3PV226 - PV229 3PV284 - PV287 3PV296 3PV301 - PV302 3PV351 3PV356 - PV357 3PW086 - PW088 3PW168 - PW171 3PW245 - PW252 3PW262 - PW264 3PW271 - PW276 3PW282 - PW292 3PW401 - PW408 3PW411 - PW418 3PW421 - PW424 3PW431 - PW435 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 14 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 15 GroupVariable Number 3PW441 - PW450 3PW521 - PW522 3PW524 - PW525 3PW527 - PW530 3PW547 - PW550 3PW621 - PW622 3PW635 - PW637 3PW831 3PW851 - PW856 2. Spares Affected None. B. Concurrent Requirements None. C. Reason 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, resulting in a rapid and uncontrolled decompression. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 15 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 16 D. Description 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. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1-2, 5: Affected Maintenance Zones ZoneModel 107, 108737-300 Group 3: Affected Maintenance Zones ZoneModel 107, 108737-400 Group 4: Affected Maintenance Zones ZoneModel 107, 108737-500 E. Compliance Group 5: 1. No Compliance is provided in this service bulletin for Group 5 airplanes. Compliance is provided in Boeing Service Bulletin 737-53-1306 for Group 5 airplanes. Group 1-4: 1. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive (AD) related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. NOTE: The Damage Tolerance Inspections (DTI's) specified in Tables 4 and 5 of Paragraph 1.E Compliance, may be used in support of compliance with 14 Code of Federal Regulations, Section 121.1109 or 129.109. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 16 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 17 2. The following FAA AD's are related to this service bulletin. Effective Date of ADAD Number July 14, 2003AD 2003-14-06 June 6, 2008AD 2008-09-13 April 13, 2010AD 2010-05-13 June 2, 2011AD 2011-08-51 January 5, 2012AD 2011-24-12 February 6, 2013AD 2012-26-02 March 14, 2014AD 2014-01-05 3. 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. 4. Any scribe line or any crack in the skin removed in accordance with PART 5 of this service bulletin and repaired in accordance with PART 6 lap joint skin modification is an approved method of repair in accordance with FAA AD 2010-05-13. 5. If an airplane had a skin panel replaced that affects S-4 lap joint skin modification areas, the compliance times and instructions for modification of the lap joint lower fastener row common to the replaced panel may be affected. Contact The Boeing Company for alternate lap joint inspection and modification instructions for lap joint areas affected by skin panel replacements and do the instructions provided by The Boeing Company. 6. Logic diagrams showing compliance tasks and compliance times are included as an aid in APPENDIX D thru APPENDIX J. 7. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. 8. 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. Group 1-4: Table 1: Internal and External Existing Local Repair Inspections Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of this service bulletin. Before 50,000 total flight cy- cles. Do PART 4: INTERNAL AND EXTERNAL EXISTING LOCAL REPAIR INSPECTIONS. All Airplanes Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 17 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 18 Group 1-4: Table 1: Internal and External Existing Local Repair Inspections Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --At the times in Table 2. Go to PART 5: PRE LAP JOINT SKIN MODIFICATION INSPEC- TIONS FOR DEFECTS. CONDITION 1: NO IN- TERNAL OR EXTER- NAL EXISTING LOCAL REPAIR FOUND DUR- ING PART 4 INSPEC- TIONS --At the times in Table 3. CONDITION 2 (ACTION 1): Contact The Boeing Company for additional repair instructions and do the additional repair. CONDITION 2: ANY INTERNAL EXISTING LOCAL REPAIR FOUND DURING PART 4 INSPECTIONS --At the times in Table 2. CONDITION 2 (ACTION 2): Go to PART 5: PRE LAP JOINT SKIN MODIFICATION INSPEC- TIONS FOR DEFECTS. --At the times in Table 3. CONDITION 3 (ACTION 1): Do Paragraph 3.B., Work Instruc- tions, Step 5.c.1. CONDITION 3: ANY EXTERNAL EXISTING LOCAL REPAIR FOUND DURING PART 4 INSPECTIONS --At the times inTable 2.CONDITION 3 (ACTION 2) DoParagraph 3.B., Work Instruc- tions, Step 5.c.2. Group 1-4: Table 2: Pre Lap Joint Skin Modification Inspections for Defects Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of this service bulletin. Before 50,000 total flight cy- cles. Do PART 5: PRE LAP JOINT SKIN MODIFICATION INSPEC- TIONS FOR DEFECTS. All Airplanes on which PART 4 inspections have been done. --At the times in Table 3. Go to PART 6: LAP JOINT SKIN MODIFICATION. CONDITION 4: NO DEFECT FOUND DURING PART 5 IN- SPECTIONS Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 18 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 19 Group 1-4: Table 2: Pre Lap Joint Skin Modification Inspections for Defects Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --Before further flight. CONDITION 5 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 5: ANY DEFECT FOUND DURING PART 5 IN- SPECTIONS --At the times in Table 3. CONDITION 5 (ACTION 2): Go to PART 6: LAP JOINT SKIN MODIFICATION. Group 1-4: Table 3: Lap Joint Skin Modification Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of this service bulletin. Before 50,000 total flight cy- cles. Do PART 6: LAP JOINT SKIN MODIFICATION. All Airplanes Group 1-4: Table 4: Inspections - Skin at Critical Fastener Rows Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 38,000 flight cycles after accomplishment of PART 6 of this service bulletin. Do PART 8: INSPECTIONS - SKIN AT CRITICAL FASTENER ROWS for any crack. (a) (b) All Airplanes 2,000 flight cycles-Repeat PART 8: INSPECTIONS - SKIN AT CRITICAL FASTEN- ER ROWS for any crack. (a) (b) CONDITION 6: NO CRACK FOUND DUR- ING PART 8 INSPEC- TIONS -Before further flight.CONDITION 7 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 7: ANY CRACK FOUND DUR- ING PART 8 INSPEC- TIONS 2,000 flight cycles-CONDITION 7 (ACTION 2): Repeat PART 8: INSPECTIONS - SKIN AT CRITICAL FASTEN- ER ROWS for any crack at the unrepaired areas. (a) (b) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 19 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 20 Group 1-4: Table 4: Inspections - Skin at Critical Fastener Rows Repeat Interval (Not to Exceed) Compliance TimeActionCondition (a) This lap joint skin modification affects Fatigue Critical Structure (FCS). These post modification inspections can also be referred to as Damage Tolerance inspections (DTI's). (b) Inspections accomplished in accordance with Table 4 are alternate structural significant Item (SSI) inspec- tions for F-48A and F-48B. Group 1-4: Table 5: Inspections - Butt Splice Structure Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 20,000 flight cycles af- ter accomplish- ment of PART 6 of this ser- vice bulletin. Before 66,000 total flight cy- cles. Do PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack. (g) (h) All Airplanes SSID F-38A: (a) (b)--Repeat PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack. (g) (h) CONDITION 8: NO CRACK FOUND DUR- ING PART 9 INSPEC- TIONS SSID F-38B: (c) SSID F-38C: (d) SSID F-38D: (e) (f) --Before further flight. CONDITION 9 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 9: ANY CRACK FOUND DUR- ING PART 9 INSPEC- TIONS SSID F-38A: (a) (b)--CONDITION 9 (ACTION 2): Repeat PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack at the unrepaired areas. (g) (h) SSID F-38B: (c) SSID F-38C: (d) SSID F-38D: (e) (f) (a) Option 1: 5,000 flight cycles after the last alternate SSI inspection F-38A accomplishment in accordance with this service bulletin. – Option 1 includes the requirement to remove one (1) fastener per airplane for an open hole inspection, therefore the inspection repeat interval is less than Option 2. (b) Option 2: 20,000 flight cycles after the last alternate SSI inspection F-38A accomplishment in accordance with this service bulletin. – Option 2 includes the requirement to remove forty (40) fasteners per airplane for open hole inspections, therefore the inspection repeat interval is greater than Option 1. (c) 24,000 flight cycles after the last alternate SSI inspection F-38B accomplishment in accordance with this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 20 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 21 Group 1-4: Table 5: Inspections - Butt Splice Structure Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (d) 24,000 flight cycles after the last alternate SSI inspection F-38C accomplishment in accordance with this service bulletin. (e) Option 1: 13,000 flight cycles after the last alternate SSI inspection F-38D accomplishment in accordance with this service bulletin. – Option 1 includes the requirement to remove one (1) fastener per airplane for an open hole inspection, therefore the inspection repeat interval is less than Option 2. (f) Option 2: 20,000 flight cycles after the last alternate SSI inspection F-38D accomplishment in accordance with this service bulletin. – Option 2 includes the requirement to remove forty (40) fasteners per airplane for open hole inspections, therefore the inspection repeat interval is greater than Option 1. (g) This lap joint skin modification affects Fatigue Critical Structure (FCS). These post modification inspections can also be referred to as Damage Tolerance inspections (DTI's). (h) Inspections accomplished in accordance with Table 5 are alternate structural significant Item (SSI) inspec- tions for F-38A, F38B, F-38C, and F-38D. Group 1-2, 4: Table 6: Alternate Structural Significant Item (SSI) Inspection for F-39B - Fuselage Crown Skin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 66,000 flight cycles after accomplishment of PART 6 of this service bulletin. Do PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN for any crack. All Airplanes 8,000 flight cycles for airplanes to which PART 10 op- tion 1 alternate SSI inspection was done or 15,000 flight cycles for air- planes to which PART 10 option 2 alternate SSI in- spection was done. -Repeat PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN for any crack. CONDITION 10: NO CRACK FOUND DUR- ING PART 10 INSPEC- TION Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 21 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 22 Group 1-2, 4: Table 6: Alternate Structural Significant Item (SSI) Inspection for F-39B - Fuselage Crown Skin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.CONDITION 11 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 11: ANY CRACK FOUND DUR- ING PART 10 INSPEC- TION 8,000 flight cycles for airplanes to which PART 10 op- tion 1 alternate SSI inspection was done or 15,000 flight cycles for air- planes to which PART 10 option 2 alternate SSI in- spection was done. -CONDITION 11 (ACTION 2): Repeat PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN for any crack at the unre- paired areas. Group 3: Table 7: Alternate Structural Significant Item (SSI) Inspection for F-39F - Fuselage Crown Skin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 66,000 flight cycles after accomplishment of PART 6 of this service bulletin. Do PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN for any crack. All Airplanes 8,000 flight cycles for airplanes to which PART 11 op- tion 1 alternate SSI inspection was done or 15,000 flight cycles for air- planes to which PART 11 option 2 alternate SSI in- spection was done. -Repeat PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN for any crack. CONDITION 12: NO CRACK FOUND DUR- ING PART 11 INSPEC- TION. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 22 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 23 Group 3: Table 7: Alternate Structural Significant Item (SSI) Inspection for F-39F - Fuselage Crown Skin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.CONDITION 13 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 13: ANY CRACK FOUND DUR- ING PART 11 INSPEC- TION. 8,000 flight cycles for airplanes to which PART 11 op- tion 1 alternate SSI inspection was done or 15,000 flight cycles for air- planes to which PART 11 option 2 alternate SSI in- spection was done. -CONDITION 13 (ACTION 2): Repeat PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN for any crack at the unre- paired areas. F. Approval 1. 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. 2. 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. 3. FAA AD 2008-09-13 mandates the Supplemental Inspection Program provided in 737-300/-400/-500 Supplemental Structural Inspection Document (SSID) D6-82669 (Revision "New"). The SSID provides inspection for Structural Significant Items (SSIs). The lap joint skin modification provided in this service bulletin will affect certain existing SSI inspections. Affected SSI inspection are now identified as "Alternate SSI Inspections". 4. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the accomplishment of the inspection methods, corrective actions, and modifications in Tables 1, 2, and 3 under Paragraph 1.E., Compliance of this service bulletin as an Alternative Method of Compliance (AMOC) to the requirements in Table 1 of Paragraph 1.F., Approval, for the paragraphs of the listed FAA Airworthiness Directives for the affected areas identified. When service bulletin specifies contacting Boeing for repair instructions, the repair must be approved by the FAA in accordance with the AD AMOC paragraph listed in Table 1 of Paragraph 1.F., Approval. All provisions of any AD in Table 1 of Paragraph 1.F., Approval, that are not specifically referenced in Table 1 of Paragraph 1.F., Approval, remain fully applicable and must be complied with accordingly. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 23 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 24 Table 1: FAA Airworthiness Directives (AD) and Alternative Method of Compliance (AMOC) AD AMOC Paragraph (Refer to footnote (E)) AMOC is only applicable in these affected areas Action/Compliance listed in SB 737-53A1343, Original Issue, that are approved as an AMOC AD Paragraph(s) Affected Associated Boeing Document AD Number (f)Areas that have been covered by the lap joint skin Inspections and modification in accordance with PART 5 and 6 (a), (b), and (c) Service Bulletin 737-53-1179 2003-14-06 modification (l)Inspection– Inspections and modification in accordance with PART 5, 6, 8, 9, 10, and 11 – Accomplish post modification alternate Structural Significant Item (SSI) inspections in accordance with Tables 4, 5, 6, and 7 of Compliance, Paragraph 1.E. (g) and (h)Supplemental Structural Inspection Document (SSID) D6-82669 2008-09-13 areas defined in PART 8, 9, 10, and 11. Refer to footnotes (A) (B) (C) (D) (y)Areas defined in PART 5 and PART 6 Inspections in accordance with PART 5 and PART 6 (g), (i), (q), and (s)(1) Alert Service Bulletin 737-53A1262 2010-05-13 (o)Areas that have been covered by the lap joint skin Inspections and modification in accordance with PART 5 and PART 6 (l)Alert Service Bulletin 737-53A1319 2015-16-08 modification (q)Areas that have been covered by the lap joint skin Inspections and modification in accordance with PART 5 and 6 (j)(2), and (n)Alert Service Bulletin 737-53A1301 2011-24-12 modification (x)Areas that have been covered by the lap joint skin Inspections and modification in accordance with PART 5 and 6 (g), (h), (i)(1), (m), (n)(1), and (p) Alert Service Bulletin 737-53A1234 2012-26-02 modification Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 24 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 25 Table 1: FAA Airworthiness Directives (AD) and Alternative Method of Compliance (AMOC) AD AMOC Paragraph (Refer to footnote (E)) AMOC is only applicable in these affected areas Action/Compliance listed in SB 737-53A1343, Original Issue, that are approved as an AMOC AD Paragraph(s) Affected Associated Boeing Document AD Number (k)Inspection– Inspections, modifications, and post modification inspections in accordance with PART 5, 6, and 9 – Accomplish post modification alternate SSI inspections in accordance with Table 5 of Compliance, Paragraph 1.E. (h)Alert Service Bulletin 737-53A1322 2014-01-05 areas defined in PART 5 and PART 9 for STA 360 and STA 908 butt splice structure only Footnotes to Table 1: (A) Post Modification Inspections: Alternate Structural Significant Item (SSI) Inspections for F-48A and F-48B - Skin at new Critical Fastener Rows (B) Post Modification Inspections: Alternate Structural Significant Item (SSI) Inspections for F-38A, F-38B, F- 38C, and F-38D - Butt Splice Structure (C) Post Modification Inspections: Alternate Structural Significant Item (SSI) Inspections for F-39B and F-39F - Fuselage Crown Skin (D) If operators choose this AMOC, then they must revise their FAA approved maintenance or inspection program to incorporate these alternative inspections. (E) Where SB 737-53A1343, Original Issue, specifies to contact Boeing for appropriate action, repair using a method approved in accordance with this AD paragraph listed in this column. 5. Group 1-2, 4: For airplanes identified in this service bulletin, original issue, the modification in this service bulletin has been reviewed as required by paragraphs (g) and (i) of AD 2008-09-13. The modification is found to affect Structural Significant Item (SSI) F-39A of SSID D6-82669, but the SSI F-39A inspection remains effective with the modification installed. Therefore, an alternative inspection is not necessary for SSI F-39A. Do the existing SSI F-39A inspection as required by paragraphs (g) and (h) of AD 2008-09-13. 6. Group 3: For airplanes identified in this service bulletin, original issue, the modification in this service bulletin has been reviewed as required by paragraphs (g) and (i) of AD 2008-09-13. The modification is found to affect Structural Significant Items (SSIs) F-38G, F-38H, and F-39E of SSID D6-82669, but the SSIs F-38G, F-38H, and F-39E inspections remain effective with the modification installed. Therefore, an alternative inspection is not necessary for SSIs F-38G, F-38H, and F-39E. Do the existing SSIs F-38G, F-38H, and F-39E inspections as required by paragraphs (g) and (h) of AD 2008-09-13. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 25 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 26 G. Manpower The table below shows an estimate of the task hours necessary to do this modification and inspection 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 inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools Group 5: No Manpower is provided for Group 5 airplanes in this service bulletin. Manpower is provided in Boeing Service Bulletin 737-53-1306 for Group 5 airplanes. Group 1-2, 4: Elapsed HoursTask HoursNumber of PersonsTask 2.254.502PART 1 10.0080.008PART 2 137.501100.008PART 3 (a)(a)2PART 4 67.65541.208PART 5 267.752142.008PART 6 137.501100.008PART 7 25.50 (b)102.00 (b)4PART 8 10.50 (b)42.00 (b)4PART 9 4.00 (b)8.00 (b)2PART 10 622.654967.70TOTAL FOR EACH AIRPLANE (a) Time required dependent upon the number and size of existing local repairs found. (b) The estimated hours for PART 8, PART 9 and PART 10 are for post-modification inspections and are not included in the total hours provided. Group 3: Elapsed HoursTask HoursNumber of PersonsTask 2.254.502PART 1 10.0080.008PART 2 137.501100.008PART 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 26 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 27 Group 3: Elapsed HoursTask HoursNumber of PersonsTask (a)(a)2PART 4 67.65541.208PART 5 268.752150.008PART 6 137.501100.008PART 7 25.50 (b)102.00 (b)4PART 8 10.50 (b)42.00 (b)4PART 9 4.00 (b)8.00 (b)2PART 11 623.654975.70TOTAL FOR EACH AIRPLANE (a) Time required dependent upon the number and size of existing local repairs found. (b) The estimated hours for PART 8, PART 9 and PART 11 are for post-modification inspections and are not included in the total hours provided. H. Weight and Balance Changes Due to the complexity of this Service Bulletin (SB) and the large number of parts removed, replaced, and installed, making an accurate determination of the weight and balance change by computation is impractical. Therefore, per Advisory Circular (AC) 120-27E, in lieu of publishing a weight and moment in this SB, the weight and moment change for this SB should be verified by re-weighing the aircraft. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 35005-302RS b. Boeing Service Bulletin 737-53-1179, 737-53-1305, 737-53-1306, 737-53A1234, 737-53A1262, 737-53A1301, 737-53A1319, 737-53A1322 c. Boeing Service Letter 737-SL-51-042 d. Boeing Service Related Problem (SRP) 737-SRP-53-0330 e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-14-06, 2008-09-13, 2010-05-13, 2011-08-51, 2011-24-12, 2012-26-02, 2014-01-05 f. Service Bulletin Index D6-19567 g. Standard Overhaul Practices Manual (SOPM) 20-30-03 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 27 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 28 h. 737 Non-Destructive Testing (NDT) Manual Part 4, 53-30-07, Part 4, 53-30-12, Part 6, 51-00-00, Part 6, 51-00-26, Part 6, 53-30-00, Part 6, 53-30-09, Part 6, 53-30-16, Part 6, 53-30-18, Part 6, 53-30-19, Part 6, 53-30-25 i. 737-300/400/500 Aircraft Maintenance Manual (AMM) 21-23-25, 25-21-25, 25-21-39, 25-21-45, 25-21-46, 25-21-71, 25-22-00, 25-23-61, 25-24-31, 25-24-41, 25-31-21, 25-31-31, 25-31-61, 25-40-01, 34-53-11 j. 737-300/400/500 Structural Repair Manual (SRM) 51-40-02, 51-50-02, 53-00-01 k. 737-300/400/500 Supplemental Structural Inspection Document (SSID) D6-82669, Revision "New". 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -C1KIT DETAIL - DOUBLER AND TRIPLER, LAP JOINT REPAIR, S-4, S-10 AND S-14 65C38192 --PL -APLDOUBLER, S4L STA 500D+6.64 - 540, 737- 400 65C38192-117 -APLDOUBLER, S4R STA 500D+6.64 - 540, 737-400 65C38192-118 -APLTRIPLER, S4L STA 500D+2.07 - 540, 737- 400 65C38192-119 -APLTRIPLER, S4R STA 500D+2.07 - 540, 737- 400 65C38192-120 -APLDOUBLER, S4L STA 727 - 727E+15.42, 737-400 65C38192-129 -APLDOUBLER, S4R STA 727 - 727E+15.42, 737-400 65C38192-130 -APLTRIPLER, S4L STA 727 - 727E+19.75, 737- 400 65C38192-131 -APLTRIPLER, S4R STA 727 - 727E+19.75, 737-400 65C38192-132 -APLTRIPLER, S4L STA 540 - 727, 737-40065C38192-139 -APLTRIPLER, S4R STA 540 - 727, 737-40065C38192-140 -APLDOUBLER, S-4L, STA 360-54065C38192-171 -APLDOUBLER, S-4R, STA 360-54065C38192-172 -APLTRIPLER, S-4L, STA 360-54065C38192-173 -APLTRIPLER, S-4R, STA 360-54065C38192-174 -APLDOUBLER, S-4L, STA 540-72765C38192-175 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 28 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 29 ADCNDCN/REVSheetTitleDrawing No -APLDOUBLER, S-4R, STA 540-72765C38192-176 -APLTRIPLER, S-4L, STA 540-72765C38192-177 -APLTRIPLER, S-4R, STA 540-72765C38192-178 -APLDOUBLER, S-4L, STA 360-500D+12.9465C38192-179 -APLDOUBLER, S-4R, STA 360-500D+12.9465C38192-180 -APLTRIPLER, S-4L, STA 360-500D+9.0665C38192-181 -APLTRIPLER, S-4R, STA 360-500D+9.0665C38192-182 -APLDOUBLER, S-4L, STA 727E+9.1-90865C38192-183 -APLDOUBLER, S-4R, STA 727E+9.1-90865C38192-184 -APLTRIPLER, S-4L, STA 727E+12.98-90865C38192-185 -APLTRIPLER, S-4R, STA 727E+12.98-90865C38192-186 --1KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38860 --2 --3 --4 -A5 -APSDLKIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38860#DL -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 360- 540 65C38860-1 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 360-540 65C38860-10 -APLDOUBLER, S-4L65C38860-11 -APLDOUBLER, S-4R65C38860-12 -APLDOUBLER, S-4L65C38860-13 -APLDOUBLER, S-4R65C38860-14 -APLDOUBLER, S-4L65C38860-15 -APLDOUBLER, S-4R65C38860-16 -APLDOUBLER, S-4L65C38860-19 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 360-540 65C38860-2 -APLDOUBLER, S-4R65C38860-20 -APLTRIPLER, S-4L65C38860-21 -APLTRIPLER, S-4R65C38860-22 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 29 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 30 ADCNDCN/REVSheetTitleDrawing No -APLTRIPLER, S-4L65C38860-23 -APLTRIPLER, S-4R65C38860-24 -APLTRIPLER, S-4L65C38860-25 -APLTRIPLER, S-4R65C38860-26 -APLTRIPLER, S-4L65C38860-29 -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 540- 727 65C38860-3 -APLTRIPLER, S-4R65C38860-30 -APLFILLER, S-465C38860-31 -APLFILLER, S-465C38860-32 -APLFILLER, S-465C38860-33 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 540-727 65C38860-4 -APLSPLICE PLATE65C38860-41 -APLSPLICE PLATE65C38860-42 -BKPLKIT - SKIN LAP REPAIR, STR-4L, STA 727- 908 65C38860-5 -APLTEAR STRAP SPLICE65C38860-51 -APLTEAR STRAP SPLICE65C38860-52 -APLTEAR STRAP SPLICE65C38860-53 -APLTEAR STRAP SPLICE65C38860-54 -APLTEAR STRAP SPLICE65C38860-55 -APLTEAR STRAP SPLICE65C38860-56 -APLTEAR STRAP SPLICE65C38860-57 -APLTEAR STRAP65C38860-58 -BPLTEAR STRAP65C38860-59 -BKPLKIT - SKIN LAP REPAIR, STR-4R, STA 727-908 65C38860-6 -APLTEAR STRAP65C38860-60 -APLTEAR STRAP65C38860-61 -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 360- 540 65C38860-9 --1KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38861 --2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 30 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 31 ADCNDCN/REVSheetTitleDrawing No --PSDLKIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38861#DL -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 360- 540 65C38861-1 -APLDOUBLER, S-4L65C38861-11 -APLDOUBLER, S-4R65C38861-12 -APLDOUBLER, S-4L65C38861-13 -APLDOUBLER, S-4R65C38861-14 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 360-540 65C38861-2 -APLTRIPLER, S-4L65C38861-21 -APLTRIPLER, S-4R65C38861-22 -APLTRIPLER, S-4L65C38861-23 -APLTRIPLER, S-4R65C38861-24 -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 727- 908 65C38861-3 -APLFILLER, S-465C38861-31 -APLFILLER, S-465C38861-32 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 727-908 65C38861-4 -APLSPLICE PLATE65C38861-41 -APLSPLICE PLATE65C38861-42 -APLTEAR STRAP SPLICE65C38861-51 -APLTEAR STRAP SPLICE65C38861-52 -APLTEAR STRAP SPLICE65C38861-53 -APLTEAR STRAP SPLICE65C38861-54 -APLTEAR STRAP SPLICE65C38861-55 --1KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38862 --2 --3 -A4 --5 --PSDLKIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38862#DL -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 360- 540 65C38862-1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 31 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 32 ADCNDCN/REVSheetTitleDrawing No -APLDOUBLER, S-4L65C38862-11 -APLDOUBLER, S-4R65C38862-12 -APLDOUBLER, S-4L65C38862-13 -APLDOUBLER, S-4R65C38862-14 -APLDOUBLER, S-4L65C38862-15 -APLDOUBLER, S-4R65C38862-16 -APLDOUBLER, S-4L65C38862-17 -APLDOUBLER, S-4R65C38862-18 -APLDOUBLER, S-4L65C38862-19 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 360-540 65C38862-2 -APLDOUBLER, S-4R65C38862-20 -APLTRIPLER, S-4L65C38862-21 -APLTRIPLER, S-4R65C38862-22 -APLTRIPLER, S-4L65C38862-23 -APLTRIPLER, S-4R65C38862-24 -APLTRIPLER, S-4L65C38862-25 -APLTRIPLER, S-4R65C38862-26 -APLTRIPLER, S-4L65C38862-27 -APLTRIPLER, S-4R65C38862-28 -APLTRIPLER, S-4L65C38862-29 -AKPLKIT - SKIN LAP REPAIR, STR-4L, STA 540- 727 65C38862-3 -APLTRIPLER, S-4R65C38862-30 -APLFILLER, S-465C38862-31 -APLFILLER, S-465C38862-32 -APLFILLER, S-465C38862-33 -APLFILLER, S-465C38862-34 -APLFILLER, S-465C38862-35 -APLFILLER, S-465C38862-36 -APLFILLER, S-465C38862-37 -AKPLKIT - SKIN LAP REPAIR, STR-4R, STA 540-727 65C38862-4 -APLSPLICE PLATE65C38862-41 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 32 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 33 ADCNDCN/REVSheetTitleDrawing No -APLSPLICE PLATE65C38862-43 -APLSPLICE PLATE65C38862-44 -BKPLKIT - SKIN LAP REPAIR, STR-4L, STA 727- 908 65C38862-5 -APLTEAR STRAP SPLICE65C38862-51 -APLTEAR STRAP SPLICE65C38862-52 -APLTEAR STRAP SPLICE65C38862-53 -APLTEAR STRAP SPLICE65C38862-54 -APLTEAR STRAP SPLICE65C38862-55 -APLTEAR STRAP SPLICE65C38862-56 -APLTEAR STRAP SPLICE65C38862-57 -APLTEAR STRAP SPLICE65C38862-58 -BKPLKIT - SKIN LAP REPAIR, STR-4R, STA 727-908 65C38862-6 -APLTEAR STRAP SPLICE65C38862-61 -APLTEAR STRAP SPLICE65C38862-62 -APLTEAR STRAP SPLICE65C38862-63 -APLTEAR STRAP SPLICE65C38862-64 -AKPLTOP KIT - SKIN LAP REPAIR, STR-4, STA 360-908 65C38863-1 -AKPLTOP KIT - SKIN LAP REPAIR, STR-4, STA 360-908 65C38863-2 -AKPLTOP KIT - SKIN LAP REPAIR, STR-4, STA 360-908 65C38864-1 -AKPLTOP KIT - SKIN LAP REPAIR, STR-4, STA 360-908 65C38865-1 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Skin Diagram Body Model 73765-73742 The table above lists applicable drawing(s) used to prepare this service bulletin. The drawing(s) are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawing(s) may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 33 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 34 None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the modification 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. 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: March 25, 2016 737-53A1343 34 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 35 2. MATERIAL INFORMATION A. Material - Price and Availability There are no Boeing Supplied kits/parts/materials for this service bulletin. The operator is to supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each Airplane. B. Industry Support Information Boeing warranty remedies are not available for the configuration changes, inspections, or modification procedures given in this service bulletin. Drawing Numbers 65C38860-3 and 65C38862-5, Sheet "LWG", Rev "A" were used by Boeing for internal modeling purposes only. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts There are no Boeing supplied kits/parts/materials for this service bulletin. 2. Parts and Materials Supplied by the Operator a. One top kit with its associated kits are necessary for each airplane. The material shown in Paragraph 2.C.2.b is also necessary for each airplane. In addition, any necessary post modification fasteners are to be procured by the operator. NOTE: The top kit does not contain any detail parts. It is only used as a collector kit to define the associated kits and engineering requirements for the detail parts on assembly and installation. Fabricate parts in accordance with the Boeing drawings listed in Paragraph 1.J.2., Data Supplied with this Service Bulletin. The individual repair doublers and repair triplers have 1.5 inches of excess length on each end and 2.0 inches of excess width both above and below the lap joint to facilitate installation with proper edge margins. Form parts in accordance with this service bulletin Work Instructions, Paragraph 3.B., Part 6, Step 1d. NOTE: Repair doubler and repair tripler drawings reference Master Dimension Surface (MDS) data. The MDS data is not required to form parts and is not provided in this service bulletin. NameTop KitQtyGroup TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38863-111 TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38863-212 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 35 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 36 NameTop KitQtyGroup TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38864-113 TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 65C38865-114 Group 1: NotesNameQtyKit Number TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 -65C38863-1 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540165C38860-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540165C38860-2 KIT - SKIN LAP REPAIR, STR-4L, STA 540-727165C38860-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727165C38860-4 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908165C38860-5 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908165C38860-6 Group 2: NotesNameQtyKit Number TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 -65C38863-2 KIT - SKIN LAP REPAIR, STR-4L, STA 540-727165C38860-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727165C38860-4 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908165C38860-5 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908165C38860-6 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540165C38860-9 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540165C38860-10 Group 3: NotesNameQtyKit Number TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 -65C38864-1 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540165C38862-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540165C38862-2 KIT - SKIN LAP REPAIR, STR-4L, STA 540-727165C38862-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727165C38862-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 36 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 37 Group 3: NotesNameQtyKit Number KIT - SKIN LAP REPAIR, STR-4L, STA 727-908165C38862-5 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908165C38862-6 Group 4: NotesNameQtyKit Number TOP KIT - SKIN LAP REPAIR, STR-4, STA 360- 908 -65C38865-1 KIT - SKIN LAP REPAIR, STR-4L, STA 540-727165C38860-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727165C38860-4 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540165C38861-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540165C38861-2 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908165C38861-3 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908165C38861-4 Group 1-2, 4: Kit 65C38860 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540 .....-65C38860-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540 ....-.65C38860-2 KIT - SKIN LAP MOD, STR-4L, STA 540-727 ...-..65C38860-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727 ..-...65C38860-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 37 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 38 Group 1-2, 4: Kit 65C38860 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908 .-....65C38860-5 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908 -.....65C38860-6 DOUBLER, S- 4L .....165C38860-11 DOUBLER, S- 4R ....1.65C38860-12 DOUBLER, S- 4L ...1..65C38860-13 DOUBLER, S- 4R ..1...65C38860-14 DOUBLER, S- 4L .1....65C38860-15 DOUBLER, S- 4R 1.....65C38860-16 TRIPLER, S- 4L .....165C38860-21 TRIPLER, S- 4R ....1.65C38860-22 TRIPLER, S- 4L ...1..65C38860-23 TRIPLER, S- 4R ..1...65C38860-24 TRIPLER, S- 4L .1....65C38860-25 TRIPLER, S- 4R 1.....65C38860-26 FILLER, S-4....1165C38860-31 FILLER, S-4..11..65C38860-32 FILLER, S-411....65C38860-33 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 38 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 39 Group 1-2, 4: Kit 65C38860 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 SPLICE PLATE 11111165C38860-41 SPLICE PLATE 22222265C38860-42 TEAR STRAP SPLICE ....121265C38860-51 TEAR STRAP SPLICE ..11..65C38860-52 TEAR STRAP SPLICE ..22..65C38860-53 TEAR STRAP SPLICE ..11..65C38860-54 TEAR STRAP SPLICE ..11..65C38860-55 TEAR STRAP SPLICE 11....65C38860-56 TEAR STRAP SPLICE 1212....65C38860-57 TEAR STRAP..11..65C38860-59 TEAR STRAP..11..65C38860-60 TEAR STRAP..11..65C38860-61 BOLT, PRO- TRUDING HD 448844BACB30NX6K4X BOLT, PRO- TRUDING HD 8820201212BACB30NX6K5X BOLT, PRO- TRUDING HD 88161688BACB30NX6K6X BOLT, PRO- TRUDING HD 224422BACB30NX6K7X (a)COLLAR--53532929BACC30M6 COLLAR2222----BACC30M6 FILLER..22..BACF3F008K020NN FILLER-FLAT262610102424BACF3F008K045NN FILLER..44..BACF3F008K055NN Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 39 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 40 Group 1-2, 4: Kit 65C38860 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 FILLER, FLAT..11..BACF3F009E141NN FILLER, FLAT....11BACF3F009E150NN FILLER, FLAT..11..BACF3F017E026NN FILLER, FLAT11....BACF3F018E026NN FILLER, FLAT....11BACF3F019E026NN FILLER1122..BACF3F020E026NN FILLER, FLAT....11BACF3F021E052NN FILLER, FLAT11....BACF3F026K030NN FILLER, FLAT....11BACF3F026K034NN FILLER, FLAT112211BACF3F026K035NN FILLER, FLAT111111BACF3F026K040NN TAPERED FILLER ..44..BACF3T01A20-19 FILLER..22..BACF3T01A25-17 FILLER, TA- PERED 11....BACF3T01B20-18 FILLER22....BACF3T01B20-20 FILLER....33BACF3T01B26-19 FILLER, TA- PERED ..11..BACF3T01B35-09 FILLER, TA- PERED ..11..BACF3T01B40-09 FILLER, TA- PERED 11....BACF3T04DD30-18 (a)RIVET, UNI- VERSAL HD 520520..470470BACR15BB6AD4C (a)RIVET, UNI- VERSAL HD 12123503501212BACR15BB6AD5C RIVET, UNI- VERSAL HD ..22..BACR15BB6D10C (a)RIVET, UNI- VERSAL HD 150150220220200200BACR15BB6D5C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 40 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 41 Group 1-2, 4: Kit 65C38860 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 (a)RIVET, UNI- VERSAL HD 120120140140310310BACR15BB6D6C (a)RIVET, UNI- VERSAL HD 610610370370380380BACR15BB6D7C RIVET, UNI- VERSAL HD 44181888BACR15BB6D8C RIVET, UNI- VERSAL HD ..66..BACR15BB6D9C RIVET, UNI- VERSAL HD 22....BACR15BB7AD6C RIVET, UNI- VERSAL HD 22....BACR15BB7AD8C RIVET, UNI- VERSAL HD 2222....BACR15BB7D6C RIVET, UNI- VERSAL HD 88....BACR15BB7D7C RIVET, UNI- VERSAL HD 1414....BACR15BB7D8C (a)RIVET169016901010101013101310BACR15GF5D5 (a)RIVET, 100 DEG 120120130130110110BACR15GF5D6 RIVET, 100 DEG 2020....BACR15GF7D6 RIVET, 100 DEG 22....BACR15GF7D7 (a) There are more parts than are necessary. Group 2: Kit 65C38860 NotesExisting Part NumberNameQtyNew Part Number -10-9 KIT - SKIN LAP REPAIR, STR- 4L, STA 360-540 .-65C38860-9 KIT - SKIN LAP REPAIR, STR- 4R, STA 360-540 -.65C38860-10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 41 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 42 Group 2: Kit 65C38860 NotesExisting Part NumberNameQtyNew Part Number -10-9 DOUBLER, S-4L.165C38860-19 DOUBLER, S-4R1.65C38860-20 TRIPLER, S-4L.165C38860-29 TRIPLER, S-4R1.65C38860-30 FILLER, S-41165C38860-31 SPLICE PLATE1165C38860-41 SPLICE PLATE2265C38860-42 TEAR STRAP SPLICE9965C38860-51 TEAR STRAP3365C38860-58 BOLT, PROTRUDING HD44BACB30NX6K4X BOLT, PROTRUDING HD1212BACB30NX6K5X BOLT, PROTRUDING HD88BACB30NX6K6X BOLT, PROTRUDING HD22BACB30NX6K7X (a)COLLAR2929BACC30M6 FILLER-FLAT1818BACF3F008K045NN FILLER, FLAT33BACF3F009E045NN FILLER, FLAT11BACF3F009E150NN FILLER, FLAT11BACF3F019E026NN FILLER, FLAT11BACF3F021E052NN FILLER, FLAT11BACF3F026K034NN FILLER, FLAT11BACF3F026K035NN FILLER, FLAT11BACF3F026K040NN FILLER33BACF3T01B26-19 (a)RIVET, UNIVERSAL HD440440BACR15BB6AD4C (a)RIVET, UNIVERSAL HD6363BACR15BB6AD5C (a)RIVET, UNIVERSAL HD260260BACR15BB6D5C (a)RIVET, UNIVERSAL HD370370BACR15BB6D6C (a)RIVET, UNIVERSAL HD350350BACR15BB6D7C RIVET, UNIVERSAL HD88BACR15BB6D8C (a)RIVET14501450BACR15GF5D5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 42 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 43 Group 2: Kit 65C38860 NotesExisting Part NumberNameQtyNew Part Number -10-9 (a)RIVET, 100 DEG270270BACR15GF5D6 (a) There are more parts than are necessary. Group 3: Kit 65C38862 NotesExisting Part Number NameQtyNew Part Number -5-4-3-2-1 KIT - SKIN LAP REPAIR, STR-4L, STA 360-540 ....-65C38862-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540 ...-.65C38862-2 KIT - SKIN LAP REPAIR, STR-4L, STA 540-727 ..-..65C38862-3 KIT - SKIN LAP REPAIR, STR-4R, STA 540-727 .-...65C38862-4 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908 -....65C38862-5 DOUBLER, S-4L....165C38862-11 DOUBLER, S-4R...1.65C38862-12 DOUBLER, S-4L....165C38862-13 DOUBLER, S-4R...1.65C38862-14 DOUBLER, S-4L..1..65C38862-15 DOUBLER, S-4R.1...65C38862-16 DOUBLER, S-4L1....65C38862-17 DOUBLER, S-4L1....65C38862-19 TRIPLER, S-4L....165C38862-21 TRIPLER, S-4R...1.65C38862-22 TRIPLER, S-4L....165C38862-23 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 43 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 44 Group 3: Kit 65C38862 NotesExisting Part Number NameQtyNew Part Number -5-4-3-2-1 TRIPLER, S-4R...1.65C38862-24 TRIPLER, S-4L..1..65C38862-25 TRIPLER, S-4R.1...65C38862-26 TRIPLER, S-4L1....65C38862-27 TRIPLER, S-4L1....65C38862-29 FILLER, S-4...1165C38862-31 FILLER, S-4...1165C38862-32 FILLER, S-4...1165C38862-33 FILLER, S-4.11..65C38862-34 FILLER, S-41....65C38862-35 FILLER, S-41....65C38862-36 FILLER, S-41....65C38862-37 SPLICE PLATE4224465C38862-41 SPLICE PLATE1..1165C38862-43 SPLICE PLATE.11..65C38862-44 TEAR STRAP SPLICE ...6665C38862-51 TEAR STRAP SPLICE ...2265C38862-52 TEAR STRAP SPLICE ...6665C38862-53 TEAR STRAP SPLICE .11..65C38862-54 TEAR STRAP SPLICE .22..65C38862-55 TEAR STRAP SPLICE .11..65C38862-56 TEAR STRAP SPLICE .11..65C38862-57 TEAR STRAP SPLICE .22..65C38862-58 TEAR STRAP SPLICE 8....65C38862-61 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 44 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 45 Group 3: Kit 65C38862 NotesExisting Part Number NameQtyNew Part Number -5-4-3-2-1 TEAR STRAP SPLICE 2....65C38862-62 TEAR STRAP SPLICE 3....65C38862-63 TEAR STRAP SPLICE 1....65C38862-64 BOLT, PROTRUD- ING HD 48844BACB30NX6K4X BOLT, PROTRUD- ING HD 412121212BACB30NX6K5X BOLT, PROTRUD- ING HD 12242488BACB30NX6K6X BOLT, PROTRUD- ING HD 24422BACB30NX6K7X (a)COLLAR.53532929BACC30M6 COLLAR22....BACC30M6 FILLER-FLAT16..1818BACF3F008K045NN FILLER.22..BACF3F008L020NN FILLER, FLAT12661010BACF3F008L045NN FILLER, FLAT.88..BACF3F008L055NN FILLER, FLAT1....BACF3F009E106NN FILLER, FLAT.11..BACF3F009E141NN FILLER, FLAT1....BACF3F009E145NN FILLER, FLAT...11BACF3F009E150NN FILLER, FLAT.11..BACF3F017E026NN FILLER, FLAT1..11BACF3F019E026NN FILLER.22..BACF3F020E026NN FILLER, FLAT1....BACF3F021E026NN FILLER, FLAT...11BACF3F021E052NN FILLER, FLAT1....BACF3F026E119NN FILLER, FLAT1....BACF3F026K030NN FILLER, FLAT...11BACF3F026K035NN Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 45 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 46 Group 3: Kit 65C38862 NotesExisting Part Number NameQtyNew Part Number -5-4-3-2-1 FILLER, FLAT...11BACF3F026K038NN FILLER, FLAT...11BACF3F026L034NN FILLER, FLAT122..BACF3F026L035NN FILLER, FLAT.11..BACF3F026L039NN FILLER, FLAT1..11BACF3F026L116NN FILLER, FLAT...11BACF3F026N053NN FILLER, FLAT1....BACF3F026N059NN FILLER, TAPERED.44..BACF3T01A20-19 FILLER.22..BACF3T01A25-17 FILLER, TAPERED1....BACF3T01B20-19 FILLER, TAPERED2....BACF3T01B20-21 FILLER...33BACF3T01B26-19 FILLER, TAPERED...11BACF3T01D28-36 FILLER, TAPERED1....BACF3T01D29-36 FILLER, TAPERED1....BACF3T04DD29-19 FILLER, TAPERED1....BACF3T07F29-26 FILLER, TAPERED...11BACF3T07F32-26 FILLER, TAPERED1....BACF3T08F29-26 FILLER, FLAT...11BACF3T08F32-26 (a)RIVET, UNIVER- SAL HD 320..360360BACR15BB6AD4C (a)RIVET, UNIVER- SAL HD 270330330220220BACR15BB6AD5C RIVET, UNIVER- SAL HD .22..BACR15BB6D11C (a)RIVET, UNIVER- SAL HD 150110110150150BACR15BB6D5C (a)RIVET, UNIVER- SAL HD 190160160180180BACR15BB6D6C (a)RIVET, UNIVER- SAL HD 650360360720720BACR15BB6D7C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 46 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 47 Group 3: Kit 65C38862 NotesExisting Part Number NameQtyNew Part Number -5-4-3-2-1 (a)RIVET, UNIVER- SAL HD 5769694747BACR15BB6D8C RIVET, UNIVER- SAL HD 31121266BACR15BB6D9C RIVET, UNIVER- SAL HD 2....BACR15BB7AD6C RIVET, UNIVER- SAL HD 2....BACR15BB7AD8C RIVET, UNIVER- SAL HD 22....BACR15BB7D6C RIVET, UNIVER- SAL HD 8....BACR15BB7D7C RIVET, UNIVER- SAL HD 12....BACR15BB7D8C RIVET, UNIVER- SAL HD 2....BACR15BB7D9C (a)RIVET173093093017501750BACR15GF5D5 (a)RIVET, 100 DEG130..130130BACR15GF5D6 (a)RIVET, 100 DEG.7070..BACR15GF5D7 RIVET, 100 DEG20....BACR15GF7D6 RIVET, 100 DEG2....BACR15GF7D7 (a) There are more parts than are necessary. Group 3: Kit 65C38862 NotesExisting Part NumberNameQtyNew Part Number -6 KIT - SKIN LAP REPAIR, STR-4R, STA 727-908 -65C38862-6 DOUBLER, S-4R165C38862-18 DOUBLER, S-4R165C38862-20 TRIPLER, S-4R165C38862-28 TRIPLER, S-4R165C38862-30 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 47 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 48 Group 3: Kit 65C38862 NotesExisting Part NumberNameQtyNew Part Number -6 FILLER, S-4165C38862-35 FILLER, S-4165C38862-36 FILLER, S-4165C38862-37 SPLICE PLATE465C38862-41 SPLICE PLATE165C38862-43 TEAR STRAP SPLICE865C38862-61 TEAR STRAP SPLICE265C38862-62 TEAR STRAP SPLICE365C38862-63 TEAR STRAP SPLICE165C38862-64 BOLT, PROTRUDING HD4BACB30NX6K4X BOLT, PROTRUDING HD4BACB30NX6K5X BOLT, PROTRUDING HD12BACB30NX6K6X BOLT, PROTRUDING HD2BACB30NX6K7X COLLAR22BACC30M6 FILLER-FLAT16BACF3F008K045NN FILLER-FLAT12BACF3F008L045NN FILLER, FLAT1BACF3F009E106NN FILLER, FLAT1BACF3F009E145NN FILLER, FLAT1BACF3F019E026NN FILLER, FLAT1BACF3F021E026NN FILLER, FLAT1BACF3F026E119NN FILLER, FLAT1BACF3F026K030NN FILLER, FLAT1BACF3F026L035NN FILLER, FLAT1BACF3F026L116NN FILLER, FLAT1BACF3F026N059NN FILLER, TAPERED1BACF3T01B20-19 FILLER, TAPERED2BACF3T01B20-21 FILLER, TAPERED1BACF3T01D29-36 FILLER, TAPERED1BACF3T04DD29- 19 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 48 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 49 Group 3: Kit 65C38862 NotesExisting Part NumberNameQtyNew Part Number -6 FILLER, TAPERED1BACF3T07F29-26 FILLER, TAPERED1BACF3T08F29-26 (a)RIVET, UNIVERSAL HD320BACR15BB6AD4C (a)RIVET, UNIVERSAL HD270BACR15BB6AD5C (a)RIVET, UNIVERSAL HD150BACR15BB6D5C (a)RIVET, UNIVERSAL HD190BACR15BB6D6C (a)RIVET, UNIVERSAL HD650BACR15BB6D7C (a)RIVET, UNIVERSAL HD57BACR15BB6D8C (a)RIVET, UNIVERSAL HD31BACR15BB6D9C RIVET, UNIVERSAL HD2BACR15BB7AD6C RIVET, UNIVERSAL HD2BACR15BB7AD8C RIVET, UNIVERSAL HD22BACR15BB7D6C RIVET, UNIVERSAL HD8BACR15BB7D7C RIVET, UNIVERSAL HD12BACR15BB7D8C RIVET, UNIVERSAL HD2BACR15BB7D9C (a)RIVET1730BACR15GF5D5 (a)RIVET, 100 DEG130BACR15GF5D6 RIVET, 100 DEG20BACR15GF7D6 RIVET, 100 DEG2BACR15GF7D7 (a) There are more parts than are necessary. Group 4: Kit 65C38861 NotesExisting Part Number NameQtyNew Part Number -4-3-2-1 KIT - SKIN LAP MOD, STR-4L, STA 360-540 ...-65C38861-1 KIT - SKIN LAP REPAIR, STR-4R, STA 360-540 ..-.65C38861-2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 49 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 50 Group 4: Kit 65C38861 NotesExisting Part Number NameQtyNew Part Number -4-3-2-1 KIT - SKIN LAP REPAIR, STR-4L, STA 727-908 .-..65C38861-3 KIT - SKIN LAP MOD, STR-4R, STA 727-908 -...65C38861-4 DOUBLER, S-4L...165C38861-11 DOUBLER, S-4R..1.65C38861-12 DOUBLER, S-4L.1..65C38861-13 DOUBLER, S-4R1...65C38861-14 TRIPLER, S-4L...165C38861-21 TRIPLER, S-4R..1.65C38861-22 TRIPLER, S-4L.1..65C38861-23 TRIPLER, S-4R1...65C38861-24 FILLER, S-4..1165C38861-31 FILLER, S-411..65C38861-32 SPLICE PLATE111165C38861-41 SPLICE PLATE222265C38861-42 TEAR STRAP SPLICE ..2265C38861-51 TEAR STRAP SPLICE ..4465C38861-52 TEAR STRAP SPLICE ..3365C38861-53 TEAR STRAP SPLICE 1010..65C38861-54 TEAR STRAP SPLICE 11..65C38861-55 BOLT, PROTRUD- ING HD 4444BACB30NX6K4X BOLT, PROTRUD- ING HD 881212BACB30NX6K5X BOLT, PROTRUD- ING HD 8888BACB30NX6K6X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 50 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 51 Group 4: Kit 65C38861 NotesExisting Part Number NameQtyNew Part Number -4-3-2-1 BOLT, PROTRUD- ING HD 2222BACB30NX6K7X (a)COLLAR..2929BACC30M6 COLLAR2222..BACC30M6 FILLER-FLAT22221818BACF3F008K045NN FILLER, FLAT..11BACF3F009E150NN FILLER, FLAT11..BACF3F018E026NN FILLER, FLAT..11BACF3F019E026NN FILLER11..BACF3F020E026NN FILLER, FLAT..11BACF3F021E052NN FILLER, FLAT11..BACF3F026K030NN FILLER, FLAT..11BACF3F026K034NN FILLER, FLAT1111BACF3F026K035NN FILLER, FLAT1111BACF3F026K040NN FILLER, TAPERED11..BACF3T01B20-18 FILLER22..BACF3T01B20-20 FILLER..33BACF3T01B26-19 FILLER, TAPERED11..BACF3T04DD30-18 (a)RIVET, UNIVER- SAL HD 450450370370BACR15BB6AD4C RIVET, UNIVER- SAL HD 12121212BACR15BB6AD5C (a)RIVET, UNIVER- SAL HD 130130180180BACR15BB6D5C (a)RIVET, UNIVER- SAL HD 110110250250BACR15BB6D6C (a)RIVET, UNIVER- SAL HD 520520300300BACR15BB6D7C RIVET, UNIVER- SAL HD 4488BACR15BB6D8C RIVET, UNIVER- SAL HD 22..BACR15BB7AD6C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 51 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 52 Group 4: Kit 65C38861 NotesExisting Part Number NameQtyNew Part Number -4-3-2-1 RIVET, UNIVER- SAL HD 22..BACR15BB7AD8C RIVET, UNIVER- SAL HD 22..BACR15BB7D6C RIVET, UNIVER- SAL HD 22..BACR15BB7D7C RIVET, UNIVER- SAL HD 1818..BACR15BB7D8C (a)RIVET1290129010201020BACR15GF5D5 (a)RIVET, 100 DEG97977979BACR15GF5D6 RIVET, 100 DEG88..BACR15GF7D6 RIVET, 100 DEG1212..BACR15GF7D7 RIVET, 100 DEG22..BACR15GF7D8 (a) There are more parts than are necessary. b. The following materials are necessary to do the change in this service bulletin. Materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator material supply to make sure all necessary materials are available. Group 1-4: NotesNameQTYPart Number / Specification (a)Chemical Conversion Coating4 PintsMIL-C-5541 (Alodine 1200S) (a)Primer4 PintsBMS 10-79, Type II or III (a)Sealant12.5 Lbs.BMS 5-95, Type I, Class B or C (a)Corrosion Inhibiting Compound8 PintsBMS 3-23, Type 2, Class II (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 52 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 53 D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin 1. Operators should review the 737 Non-Destructive Testing (NDT) Manual procedures given in Paragraph 1.J., References for NDT inspection tools needed to accomplish this service bulletin. 2. Supplementary fuselage support cradles will be required for this service bulletin. Refer to Paragraph 3.B., Work Instructions, Part 2 (Jacking and Shoring Instructions), Table 2, for information needed to fabricate the supplementary fuselage support cradles. 3. Maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can also 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: March 25, 2016 737-53A1343 53 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 54 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 54 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT BLANK PAGE ### Page 55 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 737 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 737 Aircraft Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 4. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 55 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 56 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 9. Boeing Service Letter 737-SL-51-042, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 10. Refer to APPENDIX D thru APPENDIX J for logic diagram(s). Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 11. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 12. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 13. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 14. Group 1-4: 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. 15. Some steps in the Work Instructions are labelled as Required for Compliance (RC). If this service bulletin in mandated by an Airworthiness Directive (AD), then the steps labelled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labelled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 56 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 57 16. Skin surface damage such as scribe lines, scratches, sand marks, blend-outs, nicks or gouges can lead to fatigue cracking. Scribe lines are typically made when using sharp tools to remove sealant or decals during a repainting process and are addressed in Boeing Service Bulletin 737-53A1262. 17. The definition of a defect for purposes of this service bulletin is any of the discrepancies listed in PART 5: PRE LAP JOINT SKIN MODIFICATION INSPECTIONS FOR DEFECTS. B. WORK INSTRUCTIONS Group 1-4: 1. If an airplane had a skin panel replaced that affects S-4 lap joint skin modification areas, the compliance times and modification instructions for modification of the lap joint lower fastener row common to the replaced panel may be affected. Contact The Boeing Company for alternate lap joint inspection and modification instructions for lap joint areas affected by skin panel replacements and do the instructions provided by The Boeing Company. 2. Do PART 1: SURVEY FOR ANY EXISTING LOCAL REPAIR. 3. Do PART 2: JACKING AND SHORING INSTRUCTIONS. a. Some steps and data within PART 2 are identified as Required for Compliance (RC). Any other step and data not specifically identified in PART 2 as a "RC" step is not mandatory and is not required for compliance. 4. Do PART 3: OPEN ACCESS. 5. Do PART 4: INTERNAL AND EXTERNAL EXISTING LOCAL REPAIR INSPECTIONS. a. CONDITION 1: NO INTERNAL OR EXTERNAL EXISTING LOCAL REPAIR FOUND DURING PART 4 INSPECTIONS (1) Go to PART 5: PRE LAP JOINT SKIN MODIFICATION INSPECTIONS FOR DEFECTS. b. CONDITION 2: ANY INTERNAL EXISTING LOCAL REPAIR FOUND DURING PART 4 INSPECTIONS (1) CONDITION 2: (ACTION 1): Contact The Boeing Company for additional repair instructions and do the additional repair. (2) CONDITION 2 (ACTION 2): For areas that do not have an existing repair, Go to PART 5: PRE LAP JOINT SKIN MODIFICATION INSPECTIONS FOR DEFECTS. c. CONDITION 3: ANY EXTERNAL EXISTING LOCAL REPAIR FOUND DURING PART 4 INSPECTIONS (1) CONDITION 3 (ACTION 1): Do the steps that follow: (a) Temporarily mark the perimeter of any external existing local skin repair to support scribe line inspections. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 57 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 58 (b) Remove any external existing local skin repair in accordance with FIGURE 6. (c) Do HFEC inspections for any crack in the skin in accordance with FIGURE 6. If any crack is found contact The Boeing Company for repair instructions and do the repair. (d) Additional inspections are necessary prior to continuing with the modifications and the existing external repair would need to be incorporated into the modification. Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 3 (ACTION 2): For areas that do not have an existing repair, Go to PART 5: PRE LAP JOINT SKIN MODIFICATION INSPECTIONS FOR DEFECTS. 6. Do PART 5: PRE LAP JOINT SKIN MODIFICATION INSPECTIONS FOR DEFECTS. a. CONDITION 4: NO DEFECT FOUND DURING PART 5 INSPECTIONS (1) Go to PART 6: LAP JOINT SKIN MODIFICATION. b. CONDITION 5: ANY DEFECT FOUND DURING PART 5 INSPECTIONS. (1) CONDITION 5 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 5 (ACTION 2): For areas that do not have an existing repair, Go to PART 6: LAP JOINT SKIN MODIFICATION. 7. Do PART 6: LAP JOINT SKIN MODIFICATION. 8. Do PART 7: CLOSE ACCESS. 9. Group 1-4: Do PART 8: INSPECTIONS - SKIN AT CRITICAL FASTENER ROWS for any crack. a. CONDITION 6: NO CRACK FOUND DURING PART 8 INSPECTIONS (1) Repeat PART 8: INSPECTIONS - SKIN AT CRITICAL FASTENER ROWS for any crack. b. CONDITION 7: ANY CRACK FOUND DURING PART 8 INSPECTIONS (1) CONDITION 7 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 7 (ACTION 2): Repeat PART 8: INSPECTIONS - SKIN AT CRITICAL FASTENER ROWS for any crack at the unrepaired areas. 10. Group 1-4: Do PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack. a. CONDITION 8: NO CRACK FOUND DURING PART 9 INSPECTIONS (1) Repeat PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack. b. CONDITION 9: ANY CRACK FOUND DURING PART 9 INSPECTIONS Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 58 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 59 (1) CONDITION 9 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 9 (ACTION 2): Repeat PART 9: INSPECTIONS - BUTT SPLICE STRUCTURE for any crack at the unrepaired areas. 11. Group 1-2, 4: Do PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN. a. CONDITION 10: NO CRACK FOUND DURING PART 10 INSPECTION (1) Repeat PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN for any crack. b. CONDITION 11: ANY CRACK FOUND DURING PART 10 INSPECTION (1) CONDITION 11 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 11 (ACTION 2): Repeat PART 10: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39B - FUSELAGE CROWN SKIN for any crack at the unrepaired areas. 12. Group 3: Do PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN. a. CONDITION 12: NO CRACK FOUND DURING PART 11 INSPECTION (1) Repeat PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN for any crack. b. CONDITION 13: ANY CRACK FOUND DURING PART 11 INSPECTION (1) CONDITION 13 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. (2) CONDITION 13 (ACTION 2): Repeat PART 11: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39F - FUSELAGE CROWN SKIN for any crack at the unrepaired areas. Group 5: 1. No Work Instructions are provided for Group 5 airplanes in this service bulletin. Group 5 is for 737-300 airplanes that have accomplished Boeing Service Bulletin 737-53-1306. 2. No post modification inspections are 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 59 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT ### Page 60 Group 1-4: PART 1: SURVEY FOR ANY EXISTING LOCAL REPAIR 1. Do a survey for any existing local repair in the lap joint skin modification area from STA 360 to STA 908, Stringer S-4, left and right sides. NOTE: Boeing recommends PART 1 be done to prevent possible operational disruptions. NOTE: The survey can be done via maintenance records or a general visual inspection. a. If any existing local repair is present, the operator needs to be aware that this will create additional work, beyond the scope of this service bulletin. Refer to APPENDIX B as a typical example of the additional work and data that may be required by The Boeing Company for any existing local repair. b. If no existing local repair is installed in the lap joint skin modification area from STA 360 to STA 908, Stringer S-4, left and right sides, no further action is required for PART 1. Group 1-4: PART 2: JACKING AND SHORING INSTRUCTIONS CAUTION: IF PART 2 JACKING AND SHORING INSTRUCTIONS ARE NOT DONE CORRECTLY, YOU WILL PRELOAD THE MODIFICATION, WHICH WILL INVALIDATE THE PART 8 (RC) POST MODIFICATION INSPECTIONS. USE CAUTION WHEN ACCOMPLISHING THE FUSELAGE ALIGNMENT AND SUPPORT LOADING INSTRUCTIONS. DO NOT EXCEED THE MAXIMUM LOAD ON EACH FUSELAGE SUPPORT CRADLE FOR THE FUSELAGE WHILE MAINTAINING THE AIRPLANE LEVEL. DAMAGE TO THE AIRPLANE CAN OCCUR IF THE LOADS ARE EXCEEDED. 1. Jack, level, and shore the airplane. Refer to 737-300/400/500 SRM 51-50-02 as an accepted procedure and the following instructions: a. It is recommended that components requiring removal during concurrent maintenance be removed from the airplane prior to placing it in jig position. If components are removed or installed after the airplane is in jig position, then, based on operator experience, the fuselage alignment points are to be re-checked and the airplane adjusted and supported to maintain jig position. b. Jacking, shoring, and this lap joint skin modification must be accomplished in an indoor environment. An indoor environment is one that protects the aircraft from direct sunlight, winds greater than 15 knots, and precipitation. c. All shoring components (primary jacks and fuselage support cradles) must have a means to monitor load levels throughout the lap joint skin modification and a means to ensure the maximum loads have not been exceeded at any time. d. Remove grease, lubricants, and dirt from the mating surfaces of the primary jacks, skin, wings, and stabilizer at all support locations. e. Make sure the left side loads are within +/- 250 lb of the right side loads at each similar station. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 25, 2016 737-53A1343 60 of 236 BOEING SERVICE BULLETIN 737-53A1343 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/737-53a1343/file/21373c8feb9b.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.