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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1409 Original Issue: May 04, 2023 Revision 1: October 27, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Structure Common to the Aft Drain Mast - Inspection EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
9E991ECCN:
BOEING PROPRIETARY Copyright © 2023 The Boeing Company 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: May 04, 2023 737-53A1409Revision 1: October 27, 2023 1 of 38
2.0
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 2 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION11
A. Effectivity11
1. Airplanes11
2. Spares Affected15
B. Concurrent Requirements15
C. Reason15
D. Description16
E. Compliance16
F. Approval18
G. Manpower18
H. Weight and Balance Changes19
I. Electrical Load Data19
J. References19
1. Existing Data:19
2. Data Supplied with this Service Bulletin:19
3. Installation Drawings Used in the Preparation of this Service Bulletin:20
K. Publications Affected20
L. Interchangeability and Intermixability of Parts20
M. Software Accomplishment Summary20
2. MATERIAL INFORMATION21
A. Material - Price and Availability21
B. Industry Support Information21
C. Parts Necessary for Each Airplane21
1. Kits/Parts21
2. Parts and Materials Supplied by the Operator21
3. Parts Modified and Reidentified22
4. Parts Removed and Not Replaced22
D. Parts Necessary to Change Spares22
E. Special Tooling - Price and Availability22
F. Special Tooling Necessary to do this Service Bulletin22
3. ACCOMPLISHMENT INSTRUCTIONS23
A. GENERAL INFORMATION23
B. WORK INSTRUCTIONS24
FIGURE 1: STRUCTURE COMMON TO THE AFT DRAIN MAST - INTERNAL DETAILED INSPECTION
[Group 2]27
FIGURE 2: FUSELAGE SKIN COMMON TO THE AFT DRAIN MAST - EXTERNAL DETAILED INSPECTION AND EXTERNAL SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 2]
.29
FIGURE 3: AFT WASTE WATER DRAIN MAST CLOSE ACCESS [Group 2]31
APPENDIX A: SKIN AND STRUCTURE COMMON TO THE AFT DRAIN MAST INSPECTION [Group 2] . 37 Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 3 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 4 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1409Original Issue: May 04, 2023 Revision 1: October 27, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Structure Common to the Aft Drain Mast - Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Effects of this Revision on airplanes on which Original Issue was previously done:
None.
Airplanes PA231-PA232, PC001-PC005, PG005, PG020-PG021, PG026, PG028-PG029, PG031, PG034-PG037, PG041-PG043, PG046-PG050, PG055-PG056, PG058-PG059, PG064, PG073-PG074, PG199, PG201 - PG230, PG251 - PG255, PG271 - PG279, PG301 - PG314, PG331 - PG332, PG351 - PG356, PG375, PG401
- PG403, PG431 - PG442, PG471 - PG475, PG501 - PG505, PG571 - PG583, PG584 - PG586, PG621 - PG630, PG651 - PG652, PG701 - PG705, PH001, PH011 - PH013, PH021 - PH024, PH701 - PH715, PH731 - PH732, PH741 - PH742, PH743, PJ001 - PJ002, PJ031 - PJ032, PJ071 - PJ072, PJ101 - PJ104, PJ105 - PJ113, PK026
- PK029, PK041 - PK053, PK061 - PK070, PK081 - PK082, PK091 - PK099, PK101 - PK103, PK111 - PK120, PK141 - PK146, PK203 - PK204, PK211 - PK223, PK231 - PK241, PK251 - PK258, PK271 - PK274, PK291, PK301 - PK318, PK341, PK361, PK431 - PK433, PK451 - PK452, PK511 - PK515, PK519, PK521 - PK528, PK541 - PK565, PK581, PK591 - PK599, PK601 - PK610, PK641 - PK642, PK661 - PK666, PK691 - PK697, PK711 - PK716, PK861 - PK863, PK881 - PK884, PL001, PL025 - PL028, PL061, PL101 - PL113, PL151, PL171
- PL172, PL201 - PL203, PL421, PL441, PL491, PL501 - PL506, PL581, PL601 - PL603, PL611, PL621 - PL623, PL711 - PL712, PL716, PL717 - PL735, PL756, PL758, PL761, PL781 - PL782, PL793, PL801 - PL803, PM001
- PM006, PM016 - PM017, PM021 - PM023, PM051 - PM066, PM101 - PM119, PM181, PN131 - PN163, PN401
- PN420, PN431 - PN433, PN481, PN491 - PN493, PN511 - PN512, PP101 - PP169, PP181 - PP199, PP376
- PP383, PP521 - PP522, PP631 - PP634, PP651 - PP652, PP771 - PP779, PP891 - PP899, PP901 - PP903, PP991, PQ221 - PQ237, PS651 - PS657, PS666 - PS668, PS751 - PS799, PS901 - PS941, PU001 - PU025, PX071, PX701, PY001 - PY008, PY021, PY022, PY031, PY036 - PY037, PY046 - PY048, PY051 - PY053, PY131 - PY135, PY141 - PY143, PY156 - PY157, PY161 - PY162, PY166, PY191, PY221 - PY222, PY241 - PY244, PY270 - PY275, PY281, PY286, PY301 - PY304, PY321 - PY323, PY341 - PY346, PY361 - PY362, PY381, PY401, PY409 - PY411, PY421 - PY422, PY441, PY451, PY591 - PY595, PY611 - PY612, PY621, PY631, PY651, PY671 - PY672 and PY741 were removed from Group 1 and Group 2 of this service bulletin effectivity.
REASON FOR REVISION This revision is sent to remove airplanes from the effectivity that do not have an aft waste water drain mast installed.
These sections were changed:
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 5 of 38
1. In Summary, Effectivity, updated effectivity statement.
2. In Paragraph 1.A., Effectivity, removed airplanes and changed Group Configuration descriptions.
3. In Paragraph 1.C., Reason, added Revision 1 statement.
4. In Paragraph 1.D., Description, added Revision 1 statement.
5. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added information.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY May 04, 2023Original Issue:
October 27, 2023Revision 1:
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 6 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1409Original Issue: May 04, 2023 Revision 1: October 27, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Structure Common to the Aft Drain Mast - Inspection
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 this service bulletin will make sure that any crack and any corrosion in the fuselage skin or structure common to the aft drain mast is found and repaired before it reaches a critical length. If the work given in this service bulletin is not done, any undetected crack in the fuselage skin common to the aft drain mast could result in the inability of the Principal Structural Element (PSE) to sustain limit loads, and may result in a rapid decompression of the fuselage and the loss of structural integrity of the airplane.
An operator of a 737-400 airplane reported two cracks of 0.4 inches and 0.6 inches in length, located in the fuselage skin underneath the aft drain mast. The cracks were found when an inspection was done in accordance with Boeing Service Bulletin 737-53A1318, which provides inspection instructions to make sure the drain mast is installed correctly. The reported cracks were found on an airplane that had the drain mast correctly installed and had accumulated 30,684 flight hours and 30,735 flight cycles. Boeing has determined that cracks in this location could be caused by local elevated skin stress from the elliptical cutout, aerodynamic loading effects and minor skin defects.
This service bulletin gives instructions to inspect the skin and structure common to the aft drain mast for any crack and any corrosion and to do on-condition actions.
Boeing Service Related Problem (SRP) 737-SRP-53-0646 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737-FTD-53-21002 is related to this service bulletin.
Boeing Service Bulletin 737-53A1318 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 7 of 38
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval NoAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight 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/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1:
Boeing endorses the FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplanes upon reaching the LOV, whether or not it is operated under FAA jurisdiction.
As such, Boeing no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Group 1 (line numbers 1-291) have accumulated flight cycles beyond the LOV of the maintenance program. 14 CFR 121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
Group 2:
Do an internal detailed inspection around the fastener holes, cutout, channel, and fillers for any crack and any corrosion. Do an external detailed inspection and external surface High Frequency Eddy Current (HFEC) inspection on the fuselage skin around the fastener holes and cutout for any crack and any corrosion. If any crack or any corrosion is found contact The Boeing Company for repair instructions and do the repair. If no crack and no corrosion is found, repeat the internal and external detailed inspections and external surface High Frequency Eddy Current (HFEC) inspection for any crack and corrosion.
EFFECTIVITY 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repairs given in this service bulletin.
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 8 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1409
ALERT ALERT
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
DO AN INTERNAL DETAILED INSPECTION OF THE FASTENER HOLES, CUTOUT CHANNEL, AND FILLERS FOR ANY CRACK AND ANY CORROSION. DO AN EXTERNAL
DETAILED INSPECTION AND EXTERNAL SURFACE HIGH FREQUENCY EDDY
CURRENT (HFEC) INSPECTION ON THE SKIN AROUND THE FASTENER HOLES AND CUTOUT FOR ANY CRACK AND ANY CORROSION. IF ANY CRACK OR ANY
CORROSION IS FOUND CONTACT THE BOEING COMPANY FOR REPAIR INSTRUCTIONS AND DO THE REPAIR.
3021215 Original Issue: May 04, 2023 Revision 1: October 27, 2023 Export Controlled ECCN: 9E991 737-53A1409 BOEING PROPRIETARY - See page 1 for details 9 of 38
Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 10 of 38 BOEING SERVICE BULLETIN 737-53A1409
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1409 Original Issue: May 04, 2023 Revision 1: October 27, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Structure Common to the Aft Drain Mast - Inspection
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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This bulletin is applicable to 737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 Airplane(s), line number(s) 1-12, 14-15, 17, 19, 21-28, 30-32, 34-37, 42, 48, 52, 55, 58-59, 62, 65, 74, 76, 85, 98-99, 103, 106, 108, 113, 116-120, 127, 133, 135, 137-138, 150, 174-175, 179, 183, 186-187, 191, 197-198, 200-202, 211, 302-303, 305-308, 310, 315, 317, 320, 326, 329-330, 333-337, 339-340, 343, 345-350, 354-355, 357, 359, 362-363, 370, 372, 391, 395, 405, 408, 425, 427, 436, 440, 460, 462, 479-481, 483, 493, 496-498, 500, 506-507, 510, 512, 517-518, 521, 523, 525, 527-528, 530, 536-540, 549-552, 555-560, 563-564, 566, 569-570, 572, 574-575, 577, 581-582, 584, 595-596, 598-599, 601, 612, 614, 616, 620-621, 623-629, 631-633, 635-637, 641-650, 652-654, 656-662, 664, 666-670, 672-673, 677, 684, 686, 688, 690, 693-694, 696-705, 707-710, 712-718, 720-723, 726-727, 729-730, 734-735, 737, 740, 742-746, 749-757, 760-762, 764-765, 767-772, 774, 777-778, 781, 783-786, 788-791, 793, 795, 797, 801, 803-804, 806, 808, 810, 812-813, 815, 817-819, 822-825, 831-832, 838, 840, 847-850, 855-856, 858, 861-863, 866-867, 871-872, 874-876, 884-886, 888, 890, 893, 895, 897-898, 900-901, 904, 906, 908, 910-911, 915, 917, 919-922, 925-927, 930-931, 934-937, 939, 941, 943-946, 948, 950, 952-953, 956, 958-960, 962, 966-967, 971-974, 976, 978-979, 981, 983, 986, 988-990, 992, 997-999, 1001-1002, 1007, 1015, 1022, 1030, 1032, 1039, 1043-1044, 1047, 1049-1050, 1053-1058, 1060, 1064, 1067, 1069, 1073-1075, 1077-1083, 1085-1089, 1091-1093, 1097-1099, 1102-1112, 1114-1116, 1118-1124, 1126-1127, 1129-1133, 1135, 1137, 1140-1147, 1149-1155, 1157-1159, 1162, 1164-1165, 1167, 1169-1170, 1172-1174, 1176-1181, 1188, 1190-1192, 1195, 1198, 1200, 1202, 1204, 1206-1208, 1210, 1212-1214, 1216-1223, 1225-1228, 1230, 1233-1236, 1238-1239, 1242-1248, 1250-1251, 1253-1254, 1256, 1258-1260, 1262-1264, 1266-1282, 1285-1298, 1300-1301, 1303, 1306-1309, 1314-1317, 1319-1320, 1322-1328, 1330-1336, 1338-1341, 1343, 1345-1346, 1349, 1352-1360, 1362-1368, 1370, 1372-1376, 1380-1383, 1385-1386, 1388-1391, 1393-1397, 1401-1402, 1404, 1406, 1408, 1410-1414, 1416, 1418, 1420, 1425-1435, 1437, 1439-1454, 1458, 1460-1466, 1468-1481, 1483, 1485, 1487-1493, 1495, 1497-1520, 1522-1523, 1527-1528, 1530, 1532, 1534, 1538-1544, 1546, 1548, 1550-1552, 1554-1556, 1558-1564, 1566, 1568-1570, 1572-1575, 1577, 1579-1582, 1584-1590, 1592, 1594-1605, 1607, 1609-1611, 1613, 1615-1623, 1625, 1627, 1629, Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 11 of 38
1631-1661, 1663-1674, 1676-1681, 1683-1685, 1687, 1691-1707, 1709, 1711-1716, 1720-1733, 1735-1743, 1745-1747, 1749-1765, 1767-1789, 1791-1803, 1805-1808, 1810-1822, 1824, 1827-1842, 1844-1851, 1853-1863, 1865-1868, 1870-1883, 1885-1894, 1896-1931, 1933, 1935-1939, 1941, 1943-1946, 1948-1990, 1992-2003, 2006, 2008-2016, 2018-2023, 2025-2028, 2030-2036, 2038, 2040-2052, 2054-2055, 2057, 2059-2077, 2079, 2081-2091, 2093-2102, 2104, 2106-2120, 2122-2133, 2135, 2137-2201, 2203, 2205-2223, 2225-2282, 2284, 2286, 2288-2291, 2293, 2296, 2298-2306, 2308, 2310-2321, 2323-2428, 2431-2432, 2434-2468, 2471-2472, 2474-2476, 2478-2496, 2498-2499, 2501-2503, 2505-2508, 2510-2514, 2516-2519, 2521-2569, 2571-2578, 2581-2609, 2614-2616, 2618-2625, 2630-2641, 2646-2666, 2669-2694, 2698, 2700-2701, 2703-2712, 2717-2739, 2743, 2746-2749, 2751-2752, 2756, 2760, 2763-2765, 2768-2778, 2782-2786, 2788, 2791-2794, 2800-2806, 2809-2812, 2815-2818, 2822-2839, 2844-2868, 2872-2891, 2895-2900, 2902-2914, 2919-2930, 2933-3132 in 2 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 737-100/200/200C Airplanes with an aft waste water drain mast installed, line numbers 1-291 beyond the Limit of Validity (LOV).
-1 737-200/200C/300/400/500 Airplanes with an aft waste water drain mast installed, line numbers 292-3132.
-2 Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 GroupVariable Number 1PA001 - PA022 1PA099 1PG001 - PG004 1PG006 - PG019 1PG022 - PG025 1PG027 1PG030 1PG032 - PG033 1PG038 - PG040 1PG044 - PG045 1PG051 - PG054 GroupVariable Number 1PG057 1PG060 - PG063 1PG065 - PG072 1PG075 2PJ003 - PJ009 2PJ114 - PJ119 2PJ201 - PJ219 2PJ301 - PJ302 2PJ551 - PJ561 2PJ601 - PJ615 2PJ811 GroupVariable Number 2PJ816 - PJ817 2PK201 - PK202 2PK281 - PK289 2PK351 - PK360 2PK391 2PK461 - PK469 2PK495 2PK501 - PK504 2PK611 - PK617 2PK621 - PK637 2PK671 - PK681 Export Controlled ECCN: 9E991 BOEING PROPRIETARY - See page 1 for details Original Issue: May 04, 2023 737-53A1409Revision 1: October 27, 2023 12 of 38 BOEING SERVICE BULLETIN 737-53A1409