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Commercial Airplanes 737 Requirements Bulletin ALERT Number: 737-53A1380 RB Original Issue: July 18, 2018 ATA System: 5312 SUBJECT: FUSELAGE - Stringers and Other Longitudinal Members - Overwing Emergency Exit Doors Lower Sill Splice Plate Inspection 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: July 18, 2018 737-53A1380 RB 1 of 46

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Original Issue: July 18, 2018 737-53A1380 RB 2 of 46 REQUIREMENTS BULLETIN 737-53A1380

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Table of Contents

1. EFFECTIVITY5

A. Airplanes5

B. Spares Affected5

2. CONCURRENT REQUIREMENTS5

3. COMPLIANCE5

4. APPROVAL11

5. ACCOMPLISHMENT INSTRUCTIONS13

A. General Information13

B. Work Instructions14

FIGURE 1: LEFT SIDE - LOWER SILL SPLICE PLATE S-15, STA 601 AND STA 616 - SURFACE HFEC

INSPECTION21

FIGURE 2: RIGHT SIDE - LOWER SILL SPLICE PLATE S-15, STA 601 AND STA 616 - SURFACE HFEC

INSPECTION24

FIGURE 3: LEFT SIDE LOWER SILL SPLICE PLATE - REPLACEMENT27

FIGURE 4: RIGHT SIDE LOWER SILL SPLICE PLATE - REPLACEMENT30

FIGURE 5: LEFT SIDE - STA 601 OPEN HOLE HFEC INSPECTION AND SURFACE HFEC INSPECTIONS

OF THE SKIN33

FIGURE 6: LEFT SIDE - STA 616 OPEN HOLE HFEC INSPECTION AND SURFACE HFEC INSPECTION

OF THE SKIN35

FIGURE 7: RIGHT SIDE - STA 601 OPEN HOLE HFEC INSPECTION AND SURFACE HFEC INSPECTIONS

OF THE SKIN37

FIGURE 8: RIGHT SIDE - STA 616 OPEN HOLE HFEC INSPECTION AND SURFACE HFEC INSPECTIONS

OF THE SKIN39

FIGURE 9: LEFT SIDE - LOWER SILL AND CLIP - DETAILED INSPECTION41

FIGURE 10: RIGHT SIDE - LOWER SILL AND CLIP - DETAILED INSPECTION44

Original Issue: July 18, 2018 737-53A1380 RB 3 of 46 REQUIREMENTS BULLETIN 737-53A1380

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Original Issue: July 18, 2018 737-53A1380 RB 4 of 46 REQUIREMENTS BULLETIN 737-53A1380

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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. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING

PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.

1. EFFECTIVITY A. Airplanes This bulletin is applicable to all 737-400 Airplanes, within line numbers 1487 through 3132, in 1 Group.

B. Spares Affected None.

2. CONCURRENT REQUIREMENTS None.

3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 737-53A1380 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 737-53A1380 RB mandatory.

Accomplish the required actions, based on the applicable conditions in Table 1, in accordance with Accomplishment Instructions.

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 or an OPTION do all of the ACTION numbers for that CONDITION or OPTION.

Original Issue: July 18, 2018 737-53A1380 RB 5 of 46

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TABLE 1: SURFACE HFEC INSPECTION OF THE LOWER SILL SPLICE PLATE AT S-15, IN THE INSPEC- TION AREA AT STA 601 AND STA 616, LEFT AND RIGHT SIDE Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 4,500 flight cycles after the original issue date of Requirements Bulletin 737- 53A1380 RB.

Before 11,000 total flight cycles.

ACTION 1: Do the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

All airplanes.

ACTION 2: Do the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

-Before further flight.CONDITION 1 (ACTION

1): Do the splice plate replacement on the left side.

CONDITION 1: ANY

CRACK FOUND IN THE

LEFT SIDE SPLICE

PLATE AND THE SPLICE

PLATE IS NOT SEVERED

(a) 9,000 flight cycles.-CONDITION 1 (ACTION2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

-Before further flight.Do the open hole HFEC inspections at STA 601, surface HFEC inspection of the skin and a detailed inspection of the structure at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack.

CONDITION 2: SPLICE

PLATE IS FOUND SEV- ERED IN THE STA 601

Original Issue: July 18, 2018 737-53A1380 RB 6 of 46 REQUIREMENTS BULLETIN 737-53A1380

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TABLE 1: SURFACE HFEC INSPECTION OF THE LOWER SILL SPLICE PLATE AT S-15, IN THE INSPEC- TION AREA AT STA 601 AND STA 616, LEFT AND RIGHT SIDE Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 2.1 (AC- TION 1): Contact The Boeing Company for repair instructions and do the repair.

CONDITION 2.1: ANY

CRACK FOUND -Before further flight.CONDITION 2.1 (AC- TION 2): Do the splice plate replacement on the left side.

9,000 flight cycles.-CONDITION 2.1 (AC- TION 3): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

-Before further flight.CONDITION 2.2 (AC- TION 1): Do the splice plate replacement on the left side.

CONDITION 2.2: NO

CRACK FOUND 9,000 flight cycles.-CONDITION 2.2 (AC- TION 2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

-Before further flight.Do the open hole HFEC inspections at STA 616, surface HFEC inspection of the skin and a detailed inspection of the structure at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack.

CONDITION 3: SPLICE

PLATE IS FOUND SEV- ERED IN THE STA 616

Original Issue: July 18, 2018 737-53A1380 RB 7 of 46 REQUIREMENTS BULLETIN 737-53A1380

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TABLE 1: SURFACE HFEC INSPECTION OF THE LOWER SILL SPLICE PLATE AT S-15, IN THE INSPEC- TION AREA AT STA 601 AND STA 616, LEFT AND RIGHT SIDE Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 3.1 (AC- TION 1): Contact The Boeing Company for repair instructions and do the repair.

CONDITION 3.1: ANY

CRACK FOUND -Before further flight.CONDITION 3.1 (AC- TION 2): Do the splice plate replacement on the left side.

9,000 flight cycles.-CONDITION 3.1 (AC- TION 3): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

-Before further flight.CONDITION 3.2 (AC- TION 1): Do the splice plate replacement on the left side.

CONDITION 3.2: NO

CRACK FOUND 9,000 flight cycles.-CONDITION 3.2 (AC- TION 2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

9,000 flight cycles.-Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the left side, for any crack and any severed splice plate.

CONDITION 4: NO

CRACK FOUND IN THE

LEFT SIDE SPLICE

PLATE AND THE SPLICE

PLATE IS NOT SEVERED

Original Issue: July 18, 2018 737-53A1380 RB 8 of 46 REQUIREMENTS BULLETIN 737-53A1380

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1): Do the splice plate replacement on the right side.

CONDITION 5: ANY

CRACK FOUND IN THE

RIGHT SIDE SPLICE

PLATE AND THE SPLICE

PLATE IS NOT SEVERED

(a) 9,000 flight cycles.-CONDITION 5 (ACTION2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

CONDITION 6: SPLICE

PLATE IS FOUND SEV- ERED IN THE STA 601

INSPECTION AREA ON THE RIGHT SIDE (a) -Before further flight.CONDITION 6.1 (AC- TION 1): Contact The Boeing Company for repair instructions and do the repair.

CONDITION 6.1: ANY

CRACK FOUND -Before further flight.CONDITION 6.1 (AC- TION 2): Do the splice plate replacement on the right side.

9,000 flight cycles.-CONDITION 6.1 (AC- TION 3): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

Original Issue: July 18, 2018 737-53A1380 RB 9 of 46 REQUIREMENTS BULLETIN 737-53A1380

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TABLE 1: SURFACE HFEC INSPECTION OF THE LOWER SILL SPLICE PLATE AT S-15, IN THE INSPEC- TION AREA AT STA 601 AND STA 616, LEFT AND RIGHT SIDE Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 6.2 (AC- TION 1): Do the splice plate replacement on the right side.

CONDITION 6.2: NO

CRACK FOUND 9,000 flight cycles.-CONDITION 6.2 (AC- TION 2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

-Before further flight.Do the open hole HFEC inspection at STA 616, surface HFEC inspection of the skin and a detailed inspection of the structure at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack.

CONDITION 7: SPLICE

PLATE IS FOUND SEV- ERED IN THE STA 616

INSPECTION AREA ON THE RIGHT SIDE (a) -Before further flight.CONDITION 7.1 (AC- TION 1): Contact The Boeing Company for repair instructions and do the repair.

CONDITION 7.1: ANY

CRACK FOUND -Before further flight.CONDITION 7.1 (AC- TION 2): Do the splice plate replacement on the right side.

9,000 flight cycles.-CONDITION 7.1 (AC- TION 3): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

Original Issue: July 18, 2018 737-53A1380 RB 10 of 46 REQUIREMENTS BULLETIN 737-53A1380

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TABLE 1: SURFACE HFEC INSPECTION OF THE LOWER SILL SPLICE PLATE AT S-15, IN THE INSPEC- TION AREA AT STA 601 AND STA 616, LEFT AND RIGHT SIDE Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 7.2 (AC- TION 1): Do the splice plate replacement on the right side.

CONDITION 7.2: NO

CRACK FOUND 9,000 flight cycles.-CONDITION 7.2 (AC- TION 2): Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

9,000 flight cycles.-Repeat the surface HFEC inspections of the lower sill splice plate at S-15, in the inspection area at STA 601 and STA 616, on the right side, for any crack and any severed splice plate.

CONDITION 8: NO

CRACK FOUND IN THE

RIGHT SIDE SPLICE

PLATE AND THE SPLICE

PLATE IS NOT SEVERED

(a)

(a) More than one CONDITION can be applicable.

4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document 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 document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.

Original Issue: July 18, 2018 737-53A1380 RB 11 of 46 REQUIREMENTS BULLETIN 737-53A1380

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Original Issue: July 18, 2018 737-53A1380 RB 12 of 46 REQUIREMENTS BULLETIN 737-53A1380

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