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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-55A1033 Original Issue: April 12, 1985 Revision 2: August 07, 2015 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Joint 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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 1989 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Unpublished Work.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: April 12, 1985 737-55A1033Revision 2: August 07, 2015 1 of 103
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 2 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION11
A. Effectivity11
1. Airplanes11
2. Spares Affected18
B. Concurrent Requirements18
C. Reason18
D. Description19
E. Compliance19
F. Approval38
G. Manpower39
H. Weight and Balance Changes40
I. Electrical Load Data40
J. References40
1. Existing Data:40
2. Data Supplied with this Service Bulletin:40
3. Installation Drawings Used in the Preparation of this Service Bulletin:43
K. Publications Affected43
L. Interchangeability and Intermixability of Parts43
M. Software Accomplishment Summary44
2. MATERIAL INFORMATION45
A. Material - Price and Availability45
B. Industry Support Information45
C. Parts Necessary for Each Airplane45
1. Kits/Parts:45
2. Parts and Materials Supplied by the Operator:45
3. Parts Modified and Reidentified:46
4. Parts Removed and Not Replaced:46
D. Parts Necessary to Change Spares46
E. Special Tooling - Price and Availability46
F. Special Tooling Necessary to do this Service Bulletin46
3. ACCOMPLISHMENT INSTRUCTIONS47
A. GENERAL INFORMATION47
B. WORK INSTRUCTIONS48
FIGURE 1: CENTER SECTION REAR SPAR UPPER CLEVIS LUGS DETAILED, HFEC, AND ULTRASONIC
INSPECTIONS60
FIGURE 2: HORIZONTAL STABILIZER REAR SPAR UPPER LUGS DETAILED, HFEC, AND ULTRASONIC
INSPECTIONS63
FIGURE 3: CENTER SECTION REAR SPAR UPPER CLEVIS LUGS HFEC AND DYE PENETRANT
INSPECTIONS66
FIGURE 4: HORIZONTAL STABILIZER REAR SPAR UPPER LUG HFEC AND DYE PENETRANT
INSPECTIONS68
FIGURE 5: CENTER SECTION FRONT AND REAR SPAR UPPER CLEVIS LUGS HFEC AND DYE
PENETRANT INSPECTIONS70
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 3 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
FIGURE 6: HORIZONTAL STABILIZER FRONT AND REAR SPAR UPPER LUG HFEC AND DYE
PENETRANT INSPECTIONS73
FIGURE 7: LUG PREPARATION76
FIGURE 8: BUSHING INSTALLATION80
APPENDIX A: DEFINITION FOR 0.780 INCH AND 0.932 INCH THICK REAR SPAR UPPER LUGS . . . 84
APPENDIX B: BUSHING AND SLEEVE MATERIAL AND FABRICATION87
APPENDIX C: HORIZONTAL STABILIZER INSTALLATION BOLT CONFIGURATIONS91
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 4 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-55A1033Original Issue: April 12, 1985 Revision 2: August 07, 2015 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Joint Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION This service bulletin is related to Federal Aviation Administration Airworthiness Directives FAA AD 86-12-05 and FAA AD 84-23-05. FAA AD 84-23-05 superseded FAA AD 81-11-07.
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.
The airplanes from Boeing Service Bulletin (SB) 737-55A1029 have been added to the effectivity of this service bulletin as Group 1 airplanes.
More work is necessary on airplanes that have accomplished the inspections or modifications in accordance with Revision 1 or the Original Issue of this service bulletin or Revision 1, Revision 2, Revision 3, Revision 4, or Original Revision of service bulletin 737-55A1029. Refer to Paragraph 1.E., Compliance for new compliance times.
REASON FOR REVISION This revision is sent to provide new inspection and new compliance information and repair information. This revision is also sent to change the service bulletin to Alert Status and to modify the inspection threshold information based on service related experience. This revision also replaces Boeing Service Bulletin 737-55A1029.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
Because this bulletin incorporates requirements from SB 737-55A1029 in addition to multiple formating changes, this constitutes a complete rewrite of this service bulletin.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
REVISION HISTORY April 12, 1985Original Issue:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 5 of 103
November 30, 1989Revision 1:
August 07, 2015Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 6 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-55A1033Original Issue: April 12, 1985 Revision 2: August 07, 2015 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Joint Inspection
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 During accomplishment of Service Bulletin 737-55-1026 on a Group 2 airplane with 28,704 flights, an operator detected a cracked center section rear spar upper chord clevis lug. The crack was in the forward face of the aft lug of the clevis, extending from the lug hole at the 12 o'clock position. The chord was replaced. Subsequent analysis of the cracked lug indicated fatigue was the cause of cracking. Four operators of Group 2 airplanes have also reported one airplane with cracked shim and eight airplanes with corrosion. These airplanes had between 17,160 and 42,050 flight cycles. Failure to detect cracks in the horizontal stabilizer center section rear spar clevis lugs prior to their reaching critical length may result in unscheduled spar chord replacement or loss of the horizontal stabilizer and elevator, resulting in loss of controllability of the airplane..
Group 1 airplanes were originally in Service Bulletin 737-55A1029. Revision 2 of this service bulletin replaces Service Bulletin 737-55A1029. All airplanes originally in Service Bulletin 737-55A1029 are now in Group 1 of this service bulletin.
Subsequent to the release of Revision 4 of Service Bulletin 737-55A1029, four operators of Group 1 airplanes found six airplanes with cracks in the clevis lugs while completing inspections in accordance with Service Bulletin 737-55A1029 R04. The airplanes had between 41,900 and 69,200 flight cycles.
Group 2 airplanes have thicker horizontal stabilizer center section rear spar upper chord attach lugs than earlier airplanes affected by Service Bulletin 737-55A1029, which reported cracked lugs. Subsequent to the original release of this service bulletin, two operators of Group 2 airplanes found three airplanes with cracked clevis lugs. The airplanes had between 41,900 and 69,200 flight cycles. The cracking was very similar to fatigue cracking on early airplanes reported in Service Bulletin 737-55A1029.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 7 of 103
A structural reassessment of the 737 airplane has been conducted under the requirements of the FAA Advisory Circular 91-56 in accordance with Federal Aviation Regulation (FAR) 25.571, as amended in 1978, to ensure safe operation of 737 airplanes throughout their operational life. As a result of this reassessment, the structure affected by this service bulletin has been determined to be structurally significant in that it is critical to the structural integrity of the airplane and should be inspected in accordance with a Flight Safety Inspection Program.
The integrity of the horizontal stabilizer rear spar terminal fittings, which comprise of the center section clevis lugs and the outboard section lugs, is dependent on the integrity of the front spar terminal fittings. Therefore, a flight safety inspection program describing inspections necessary to maintain the structural integrity of the airplane must include the front and rear spar terminal fittings and are defined in this service bulletin.
As a result of the FAA-sponsored Aging Fleet Conference, a 737 Structures Working Group with Airline and Boeing members and FAA observers was formed to review structural service bulletin modifications and recommend selected bulletins for incorporation on aging airplanes.
Boeing Fleet Team Digest (FTD) 737 FTD 55-02001 is related to this service bulletin.
ACTION Get access to the horizontal stabilizers and center section rear spar upper lugs. At the times specified in Paragraph
1.E., Compliance, do PART 2 Detailed and High Frequency Eddy Current (HFEC) and Ultrasonic inspections of the horizontal stabilizer and center section lugs to detect any crack indication. Based on inspection findings do PART 2 repeat inspections or PART 3 to confirm crack indication. Based on inspection findings in PART 3, do PART 2 repeat inspections or PART 3A inspection and subsequent corrective actions.
EFFECTIVITY 737-100/-200/-200C airplanes. See Paragraph 1.A.1., Airplane(s), for effectivity.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
FAA AD 86-12-05 and FAA AD 84-23-05 are related to this service bulletin. FAA AD 84-23-05 superseded FAA AD 81-11-07.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 8 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
BOEING SERVICE BULLETIN 737-55A1033
ALERT ALERT
SCHEDULED INSPECTION
FOR CRACKS ON
HORIZONTAL STABILIZER
FRONT SPAR JOINTS
INSPECT FOR CRACKS ON HORIZONTAL
STABILIZER UPPER REAR SPAR JOINTS
AND SCHEDULED INSPECTION FOR
CRACKS ON HORIZONTAL STABILIZER REAR SPAR JOINTS.
2350416 Original Issue: April 12, 1985 Revision 2: August 07, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-55A1033 Work - See page 1 for details. 9 of 103
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 10 of 103 BOEING SERVICE BULLETIN 737-55A1033
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-55A1033 Original Issue: April 12, 1985 Revision 2: August 07, 2015 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Joint Inspection
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 Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 31913 for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 737-100/200/200C Airplanes. Line numbers 1 through 315, 323 and
324. Airplanes with 0.780 inch thick horizontal stabilizer center section rear spar upper chord clevis lugs installed in production.
-1 Airplanes with 0.780 inch thick horizontal stabilizer center section rear spar upper chord clevis lugs as of the release date of Revision 2 of this service bulletin.
1 Airplanes that have 0.932 inch thick horizontal stabilizer center section rear spar upper chord clevis lugs as of the release date of Revision 2 of this service bulletin.
2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 11 of 103
DESCRIPTIONCONFIGURATIONGROUP 737-200/200C Airplanes. Line numbers 316 through 322 and Line Number 325 and on. These airplanes have 0.932 inch thick horizontal stabilizer center section rear spar upper chord clevis lugs installed in production.
-2 Airplane Models:
737-100, 737-200, 737-200C GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG301 - PG314 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 1PH001 1PH011 2PH012 - PH013 2PH021 - PH024 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 12, 1985 737-55A1033Revision 2: August 07, 2015 12 of 103 BOEING SERVICE BULLETIN 737-55A1033