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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1368 Original Issue: February 27, 2018 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Lower Bulkhead Chords at Body Station 540 - Inspection, Repair and Preventive Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: February 27, 2018 737-53A1368 1 of 545

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Original Issue: February 27, 2018 737-53A1368 2 of 545 BOEING SERVICE BULLETIN 737-53A1368

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Table of Contents

Summary9

1. PLANNING INFORMATION15

A. Effectivity15

1. Airplanes15

2. Spares Affected38

B. Concurrent Requirements38

C. Reason38

D. Description39

E. Compliance41

F. Approval53

G. Manpower54

H. Weight and Balance Changes84

I. Electrical Load Data90

J. References90

1. Existing Data:90

2. Data Supplied with this Service Bulletin:91

3. Installation Drawings Used in the Preparation of this Service Bulletin:91

K. Publications Affected91

L. Interchangeability and Intermixability of Parts92

M. Software Accomplishment Summary92

2. MATERIAL INFORMATION93

A. Material - Price and Availability93

B. Industry Support Information96

C. Parts Necessary for Each Airplane96

1. Kits/Parts96

2. Parts and Materials Supplied by the Operator105

3. Parts Modified and Reidentified107

4. Parts Removed and Not Replaced107

D. Parts Necessary to Change Spares107

E. Special Tooling - Price and Availability107

F. Special Tooling Necessary to do this Service Bulletin107

3. ACCOMPLISHMENT INSTRUCTIONS109

A. GENERAL INFORMATION109

B. WORK INSTRUCTIONS111

FIGURE 1: LEFT SIDE - STA 540 - SKIN - ULTRASONIC INSPECTION [Group 1, Configuration 2, 4-5;

Group 2, Configuration 2, 4-5; Group 3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5;

Group 5-8]131

FIGURE 2: RIGHT SIDE - STA 540 - SKIN - ULTRASONIC INSPECTION [Group 1, Configuration 2-3, 5;

Group 2, Configuration 2-3, 5; Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5;

Group 5-8]133

FIGURE 3: LEFT SIDE - STA 540 - REPAIR TRIPLER - ULTRASONIC INSPECTION [Group 1, Configuration 1-3, 5; Group 2, Configuration 1-3, 5; Group 3, Configuration 1-3, 5; Group 4, Configuration 1-3,

5; Group 5-8]135

FIGURE 4: RIGHT SIDE - STA 540 - REPAIR TRIPLER - ULTRASONIC INSPECTION [Group 1, Configuration 1-2, 4-5; Group 2, Configuration 1-2, 4-5; Group 3, Configuration 1-2, 4-5; Group

4, Configuration 1-2, 4-5; Group 5-8]138

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FIGURE 5: LEFT SIDE - STA 540 - SKIN AND BULKHEAD CHORD OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2, 4-5; Group 2, Configuration 2, 4-5; Group 3, Configuration 2, 4-5;

Group 4, Configuration 2, 4-5; Group 5-8]141

FIGURE 6: RIGHT SIDE - STA 540 - SKIN AND BULKHEAD CHORD OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2-3, 5; Group 2, Configuration 2-3, 5; Group 3, Configuration 2-3, 5;

Group 4, Configuration 2-3, 5; Group 5-8]143

FIGURE 7: LEFT SIDE - STA 540 - SKIN, TRIPLER, DOUBLER, AND BULKHEAD CHORD - OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1, 3; Group 2, Configuration 1, 3; Group 3,

Configuration 1, 3; Group 4, Configuration 1, 3]145

FIGURE 8: RIGHT SIDE - STA 540 - SKIN, TRIPLER, DOUBLER, AND BULKHEAD CHORD - OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1, 4; Group 2, Configuration 1, 4; Group 3,

Configuration 1, 4; Group 4, Configuration 1, 4]147

FIGURE 9: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY REMOVAL [Group 1, Configuration 2, 4-5;

Group 3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]149

FIGURE 10: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY REMOVAL [Group 1, Configuration 2-3, 5;

Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]153

FIGURE 11: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY REMOVAL [Group 2, Configuration 2, 4-5;

Group 6]157

FIGURE 12: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY REMOVAL [Group 2, Configuration 2-3, 5;

Group 6]161

FIGURE 13: LEFT SIDE - STA 540 - SKIN - SURFACE HFEC INSPECTION UNDER THE DRAG LINK ASSEMBLY [Group 1, Configuration 2, 4-5; Group 2, Configuration 2, 4-5; Group 3, Configuration

2, 4-5; Group 4, Configuration 2, 4-5; Group 5-8]165

FIGURE 14: RIGHT SIDE - STA 540 - SKIN - SURFACE HFEC INSPECTION UNDER THE DRAG LINK ASSEMBLY [Group 1, Configuration 2-3, 5; Group 2, Configuration 2-3, 5; Group 3, Configuration

2-3, 5; Group 4, Configuration 2-3, 5; Group 5-8]168

FIGURE 15: LEFT SIDE - STA 540 - SKIN - CRACK CUT OUT [Group 1-4, Configuration 5; Group 5-8] .171 FIGURE 16: RIGHT SIDE - STA 540 - SKIN - CRACK CUT OUT [Group 1-4, Configuration 5; Group 5-8]

.174

FIGURE 17: LEFT SIDE - STA 540 - SKIN - CRACK CUT OUT [Group 1, Configuration 2, 4; Group 2,

Configuration 2, 4; Group 3, Configuration 2, 4; Group 4, Configuration 2, 4]177

FIGURE 18: RIGHT SIDE - STA 540 - SKIN - CRACK CUT OUT [Group 1, Configuration 2-3; Group 2,

Configuration 2-3; Group 3, Configuration 2-3; Group 4, Configuration 2-3]180

FIGURE 19: LEFT SIDE - STA 540 - STRINGER 22 - CUT [Group 1-4, Configuration 5]183

FIGURE 20: RIGHT SIDE - STA 540 - STRINGER 22 - CUT [Group 1-4, Configuration 5]185

FIGURE 21: LEFT SIDE - STA 540 BULKHEAD CHORD - OPEN HOLE HFEC INSPECTION [Group 1-4,

Configuration 5]187

FIGURE 22: RIGHT SIDE - STA 540 BULKHEAD CHORD - OPEN HOLE HFEC INSPECTION [Group 1-4,

Configuration 5]189

FIGURE 23: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 1-3, Configuration

5]191

FIGURE 24: RIGHT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 1-4, Configuration

5]193

FIGURE 25: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 4, Configuration

5]195

FIGURE 26: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 1-3, Configuration

5]197

FIGURE 27: RIGHT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 1-4, Configuration

5]199

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FIGURE 28: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 4, Configuration

5]201

FIGURE 29: LEFT SIDE - STA 540 - DOUBLER, TRIPLER AND FILLER FABRICATION [Group 1, Configuration 2, 4-5; Group 3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]

.203

FIGURE 30: RIGHT SIDE - STA 540 - DOUBLER, TRIPLER AND FILLER FABRICATION [Group 1, Configuration 2-3, 5; Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]

.210

FIGURE 31: LEFT SIDE - STA 540 - DOUBLER, TRIPLER AND FILLER FABRICATION [Group 2,

Configuration 2, 4-5; Group 6]217

FIGURE 32: RIGHT SIDE - STA 540 - DOUBLER, TRIPLER AND FILLER FABRICATION [Group 2,

Configuration 2-3, 5; Group 6]224

FIGURE 33: LEFT SIDE - STA 540 - SHIM AND REPAIR ANGLE FABRICATION [Group 1, Configuration 2, 4-5; Group 2, Configuration 2, 4-5; Group 3, Configuration 2, 4-5; Group 4, Configuration 2,

4-5; Group 5-8]231

FIGURE 34: RIGHT SIDE - STA 540 - SHIM AND REPAIR ANGLE FABRICATION [Group 1, Configuration 2-3, 5; Group 2, Configuration 2-3, 5; Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3,

5; Group 5-8]234

FIGURE 35: LEFT SIDE - STA 540 - FASTENER REMOVAL [Group 1, Configuration 2, 4-5; Group 3,

Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]237

FIGURE 36: RIGHT SIDE - STA 540 - FASTENER REMOVAL [Group 1, Configuration 2-3, 5; Group 3,

Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]241

FIGURE 37: LEFT SIDE - STA 540 - FASTENER REMOVAL [Group 2, Configuration 2, 4-5; Group 6] . 245 FIGURE 38: RIGHT SIDE - STA 540 - FASTENER REMOVAL [Group 2, Configuration 2-3, 5; Group 6] .249 FIGURE 39: LEFT SIDE - STA 540 - REPAIR INSTALLATION [Group 1, Configuration 2, 4-5; Group 3,

Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]253

FIGURE 40: RIGHT SIDE - STA 540 - REPAIR INSTALLATION [Group 1, Configuration 2-3, 5; Group 3,

Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]260

FIGURE 41: LEFT SIDE - STA 540 - REPAIR INSTALLATION [Group 2, Configuration 2, 4-5; Group 6] .267 FIGURE 42: RIGHT SIDE - STA 540 - REPAIR INSTALLATION [Group 2, Configuration 2-3, 5; Group 6]

.274

FIGURE 43: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 1-3, Configuration

5]281

FIGURE 44: RIGHT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 1-4, Configuration

5]284

FIGURE 45: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE PREPARATION [Group 4, Configuration

5]287

FIGURE 46: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 1-3, Configuration

5]290

FIGURE 47: RIGHT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 1-4, Configuration

5]293

FIGURE 48: LEFT SIDE - STA 540 BULKHEAD CHORD - SPLICE INSTALLATION [Group 4, Configuration

5]296

FIGURE 49: LEFT SIDE - STA 540 - RAM AIR INLET REPAIR [Group 1, Configuration 2, 4-5; Group 3,

Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]299

FIGURE 50: RIGHT SIDE - STA 540 - RAM AIR INLET REPAIR [Group 1, Configuration 2-3, 5; Group 3,

Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]305

FIGURE 51: LEFT SIDE - STA 540 - RAM AIR INLET REPAIR [Group 2, Configuration 2, 4-5; Group 6] .311 FIGURE 52: RIGHT SIDE - STA 540 - RAM AIR INLET REPAIR [Group 2, Configuration 2-3, 5; Group 6]

.317

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FIGURE 53: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 1, Configuration 2,

4-5; Group 5]323

FIGURE 54: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 1, Configuration

2-3, 5; Group 5]332

FIGURE 55: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 3, Configuration 2,

4-5; Group 4, Configuration 2, 4-5; Group 7-8]341

FIGURE 56: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 3, Configuration

2-3, 5; Group 4, Configuration 2-3, 5; Group 7-8]349

FIGURE 57: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 2, Configuration 2,

4-5; Group 6]357

FIGURE 58: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 2, Configuration

2-3, 5; Group 6]365

FIGURE 59: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 1, Configuration 2,

4-5; Group 5]373

FIGURE 60: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 1, Configuration

2-3, 5; Group 5]382

FIGURE 61: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 3, Configuration 2,

4-5; Group 4, Configuration 2, 4-5; Group 7-8]391

FIGURE 62: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 3, Configuration

2-3, 5; Group 4, Configuration 2-3, 5; Group 7-8]400

FIGURE 63: LEFT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 2, Configuration 2,

4-5; Group 6]409

FIGURE 64: RIGHT SIDE - STA 540 - DRAG LINK ASSEMBLY INSTALLATION [Group 2, Configuration

2-3, 5; Group 6]417

FIGURE 65: LEFT SIDE - STA 540 - RADIUS FILLER INSTALLATION425

FIGURE 66: RIGHT SIDE - STA 540 - RADIUS FILLER INSTALLATION429

FIGURE 67: LEFT SIDE - STA 540 - TERMINATION FITTING SPACER FABRICATION433

FIGURE 68: RIGHT SIDE - STA 540 - TERMINATION FITTING SPACER FABRICATION436

FIGURE 69: LEFT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 1, 3, 5, 7-8] . 439 FIGURE 70: RIGHT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 1, 3-5, 7-8] . 444

FIGURE 71: LEFT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 2, 6]449

FIGURE 72: RIGHT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 2, 6]454

FIGURE 73: LEFT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 1, Configuration 2,

4-5; Group 3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]459

FIGURE 74: RIGHT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 1, Configuration

2-3, 5; Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]464

FIGURE 75: LEFT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 2, Configuration 2,

4-5; Group 6]469

FIGURE 76: RIGHT SIDE - STA 540 - TERMINATION FITTING INSTALLATION [Group 2, Configuration

2-3, 5; Group 6]474

FIGURE 77: LEFT SIDE - STA 540 - SKIN DETAILED INSPECTION [Group 1, Configuration 2, 4-5; Group

3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]479

FIGURE 78: RIGHT SIDE - STA 540 - SKIN DETAILED INSPECTION [Group 1, Configuration 2-3, 5; Group

3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]483

FIGURE 79: LEFT SIDE - STA 540 - SKIN DETAILED INSPECTION [Group 2, Configuration 2, 4-5; Group

6]487

FIGURE 80: RIGHT SIDE - STA 540 - SKIN DETAILED INSPECTION [Group 2, Configuration 2-3, 5; Group

6]491

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FIGURE 81: LEFT SIDE - STA 540 - SKIN LFEC INSPECTION [Group 1, Configuration 2, 4-5; Group 3,

Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5, 7-8]495

FIGURE 82: RIGHT SIDE - STA 540 - SKIN LFEC INSPECTION [Group 1, Configuration 2-3, 5; Group 3,

Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5, 7-8]498

FIGURE 83: LEFT SIDE - STA 540 - SKIN LFEC INSPECTION [Group 2, Configuration 2, 4-5; Group 6]

.501

FIGURE 84: RIGHT SIDE - STA 540 - SKIN LFEC INSPECTION [Group 2, Configuration 2-3, 5; Group 6]

.504

FIGURE 85: LEFT SIDE - STA 540 - INTERNAL SKIN HFEC INSPECTION [Group 1, Configuration 2, 4-5;

Group 2, Configuration 2, 4-5; Group 3, Configuration 2, 4-5; Group 4, Configuration 2, 4-5;

Group 5-8]507

FIGURE 86: RIGHT SIDE - STA 540 - INTERNAL SKIN HFEC INSPECTION [Group 1, Configuration 2-3, 5; Group 2, Configuration 2-3, 5; Group 3, Configuration 2-3, 5; Group 4, Configuration 2-3, 5;

Group 5-8]510

FIGURE 87: LEFT SIDE - STA 540 - SPLICE STRAP AND BULKHEAD OUTER CHORD HFEC INSPECTIONS [Group 1, Configuration 2, 4-5; Group 2, Configuration 2, 4-5; Group 3,

Configuration 2, 4-5; Group 4, Configuration 2, 4-5; Group 5-8]513

FIGURE 88: RIGHT SIDE - STA 540 - SPLICE STRAP AND BULKHEAD OUTER CHORD HFEC INSPECTIONS [Group 1, Configuration 2-3, 5; Group 2, Configuration 2-3, 5; Group 3,

Configuration 2-3, 5; Group 4, Configuration 2-3, 5; Group 5-8]516

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 1: INSPECTION, REPAIR

AND MODIFICATION FOR AIRPLANES THAT DO NOT HAVE AN EXISTING REPAIR INSTALLED [Group 1, Configuration 2, 5; Group 2, Configuration 2, 5; Group 3, Configuration

2, 5; Group 4, Configuration 2, 5; Group 5-8]519

APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 2: INSPECTION, REPAIR

AND MODIFICATION FOR AIRPLANES THAT HAVE A REPAIR INSTALLED ON THE LEFT

SIDE AND A PREVENTIVE MODIFICATION INSTALLED ON THE RIGHT SIDE OF THE

AIRPLANE. [Group 1-4, Configuration 3]522

APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 3: INSPECTION, REPAIR

AND MODIFICATION FOR AIRPLANES THAT HAVE A REPAIR INSTALLED ON THE RIGHT

SIDE AND A PREVENTIVE MODIFICATION INSTALLED ON THE LEFT SIDE OF THE

AIRPLANE. [Group 1-4, Configuration 4]527

APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 4: INSPECTION, REPAIR

AND MODIFICATION FOR AIRPLANES THAT HAVE AN EXISTING REPAIR INSTALLED ON BOTH THE LEFT AND RIGHT SIDE OF THE AIRPLANE. [Group 1-4, Configuration 1] . 532 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 5: POST REPAIR ULTRASONIC INSPECTIONS [Group 1, Configuration 2-5; Group 2, Configuration 2-5; Group

3, Configuration 2-5; Group 4, Configuration 2-5; Group 5-8]534

APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 6: POST REPAIR EDDY CURRENT INSPECTIONS [Group 1, Configuration 2-5; Group 2, Configuration 2-5; Group 3,

Configuration 2-5; Group 4, Configuration 2-5; Group 5-8]535

APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 7: POST REPAIR DETAILED INSPECTIONS [Group 1, Configuration 2-5; Group 2, Configuration 2-5; Group 3, Configuration

2-5; Group 4, Configuration 2-5; Group 5-8]536

APPENDIX H: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 8: POST PREVENTIVE

MODIFICATION INSPECTIONS537

APPENDIX I: FORMING AND FITTING REQUIREMENTS FOR DETAIL METAL PARTS539

APPENDIX J: AIRPLANE JACKING REQUIREMENTS [Group 1, Configuration 2-5; Group 2, Configuration

2-5; Group 3, Configuration 2-5; Group 4, Configuration 2-5; Group 5-8]542

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APPENDIX K: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE REPAIR ANGLE [Group 1, Configuration 2-5; Group 2, Configuration 2-5; Group 3, Configuration 2-5; Group 4,

Configuration 2-5; Group 5-8]543

APPENDIX L: PART DEMAND INTENT545

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1368Original Issue: February 27, 2018 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Lower Bulkhead Chords at Body Station 540 - Inspection, Repair and Preventive Modification

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of the inspection and preventive modification or repair given in this service bulletin will mitigate cracking in the station (STA) 540 bulkhead chord and skin at stringer S-22, left and right side of the airplane.

Cracking in the STA 540 bulkhead chord or skin can potentially result in the inability of a primary structural element to sustain limit load. If cracking is not detected and repaired, it can result in possible rapid decompression and loss of structural integrity.

Multiple operators have reported cases of cracks in the skin and the STA 540 bulkhead chord at the three fastener locations common to the drag link assembly at the STA 540 bulkhead chord. The cracks were found during the accomplishment of Boeing Service Bulletin 737-53-1294. The crack findings indicate that fatigue stresses in this area may be higher than predicted and current maintenance inspections do not provide adequate opportunity for cracks to be detected.

History of Reported Skin Cracks Under the Drag Link Hole 2 Crack Length Hole 1 Crack Length Side (Left / Right) Flight Cycles Flight Hours Model

0.0660.130R33,32857,275737-700

0.012-L16,28647,791737-800

0.072-L24,71642,846737-700

0.058-L18,14643,811737-800 -0.030L24,92942,749737-700

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History of Reported Skin Cracks Under the Drag Link Hole 2 Crack Length Hole 1 Crack Length Side (Left / Right) Flight Cycles Flight Hours Model

0.066-L22,28143,342737-800

0.012-L25,18242,954737-800 Accomplishment of this service bulletin will find and repair any crack and prevent any future cracking at the STA bulkhead 540 chord.

Boeing Fleet Team Digest (FTD) 737NG FTD 53-16001 is related to this service bulletin.

Boeing Service Related Problem (SRP) 737NG-SRP-53-0496 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required 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 38275-206S) Group 1, Configuration 2-5; Group 2, Configuration 2-5; Group 3, Configuration 2-5; Group 4, Configuration 2-5; Group 5-8:

1. Do an ultrasonic inspection for any crack in the skin on the side or sides of the airplane with no repair installed.

2. If any crack is found during the ultrasonic inspection do open hole High Frequency Eddy Current (HFEC) inspections and surface HFEC inspections for any crack.

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3. If no crack is found during the ultrasonic inspection do open hole High Frequency Eddy Current (HFEC) inspections and surface HFEC inspections for any crack or repeat the ultrasonic inspections at the time given in Paragraph 1.E., Compliance.

4. If any crack is found in the skin at the first three fasteners forward of the wing during the open hole HFEC and surface HFEC inspections, do the repair. If any crack is found at any other location contact The Boeing Company for repair instructions and do the repair. If no crack is found do the preventive modification.

5. Do post repair or post preventive modification inspections for any crack.

Group 1, Configuration 1, 3-4; Group 2, Configuration 1, 3-4; Group 3, Configuration 1, 3-4; Group 4, Configuration 1, 3-4:

1. Do an ultrasonic inspection for any crack in the repair tripler on the side or sides of the airplane with a repair installed.

2. If any crack is found during the ultrasonic inspection contact The Boeing Company for repair instructions and do the repair.

3. If no crack is found during the ultrasonic inspection do open hole High Frequency Eddy Current (HFEC) inspections for any crack or repeat the ultrasonic inspections at the time given in Paragraph 1.E., Compliance.

4. If any crack is found in the skin during the open hole HFEC inspections, contact The Boeing Company for repair instructions and do the repair. If no crack is found do the preventive modification.

5. Do post preventive modification inspections for any crack.

EFFECTIVITY 737-600, -700, -700C, -800, -900, and -900ER 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 inspection, and/or repair procedures given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

Original Issue: February 27, 2018 737-53A1368 11 of 545 BOEING SERVICE BULLETIN 737-53A1368

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MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

Operators are encouraged to complete the survey provided in APPENDIX L of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Original Issue: February 27, 2018 737-53A1368 12 of 545 BOEING SERVICE BULLETIN 737-53A1368

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