# Boeing Alert Service Bulletin 737-57A1269: Revision 2

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- Document: [Boeing Alert Service Bulletin 737-57A1269](https://openairdocs.org/service-documents/boeing/737-57a1269.md)
- Title as filed: SB-737-57A1269-02--BOEING
- Pages: 241
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### Page 1

Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-57A1269
Original Issue: December 04, 2003
Revision 2: October 11, 2018
ATA System: 5712
SUBJECT: WINGS - Wing Center Section Rear Spar - Replacement of Stiffeners at Left and Right
BBL 6.15
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 © 2003 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Unpublished Work.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: December 04, 2003
737-57A1269Revision 2: October 11, 2018
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Table of Contents
Revision Transmittal Sheet ............................................ 7
S u m m a r y  ..................................................... 1 1
1. PLANNING INFORMATION ........................................ 1 5
A . E f f e c t i v i t y  ............................................... 1 5
1. Airplanes ............................................ 1 5
2 . S p a r e s  A f f e c t e d  ........................................ 3 3
B. Concurrent Requirements ...................................... 3 3
C. Reason ................................................ 3 3
D. Description .............................................. 3 5
E. Compliance .............................................. 3 7
F . A p p r o v a l  ............................................... 3 8
G. Manpower .............................................. 3 9
H. Weight and Balance Changes .................................... 4 0
I. Electrical Load Data ......................................... 4 0
J . R e f e r e n c e s  .............................................. 4 0
1. Existing Data: ......................................... 4 0
2. Data Supplied with this Service Bulletin: ........................... 4 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 1
K. Publications Affected ........................................ 4 1
L. Interchangeability and Intermixability of Parts ........................... 4 1
M. Software Accomplishment Summary ................................ 4 1
2. MATERIAL INFORMATION ........................................ 4 3
A. Material - Price and Availability ................................... 4 3
B. Industry Support Information .................................... 4 4
C. Parts Necessary for Each Airplane ................................. 4 5
1 . K i t s / P a r t s :  ........................................... 4 5
2. Parts and Materials Supplied by the Operator: ........................ 5 3
3. Parts Modified and Reidentified: ............................... 5 4
4. Parts Removed and Not Replaced: .............................. 5 4
D. Parts Necessary to Change Spares ................................. 5 4
E. Special Tooling - Price and Availability ............................... 5 5
F. Special Tooling Necessary to do this Service Bulletin ....................... 5 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 7
A. GENERAL INFORMATION ..................................... 5 7
B. WORK INSTRUCTIONS ....................................... 5 8
F I G U R E  1 : T H I S  F I G U R E  I S  D E L E T E D .................................. 6 6
FIGURE 2: LEFT SIDE BRACKET REMOVALS [Group 1, Configuration 1, 3; Group 3, Configuration 1, 3;
Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] .................. 6 7
FIGURE 3: RIGHT SIDE BRACKET REMOVALS [Group 1, Configuration 1, 3; Group 3, Configuration 1,
3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] ................. 7 1
FIGURE 4: ANGLE REMOVAL [Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4,
Configuration 1, 3; Group 5, Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7,
Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .................. 7 6
FIGURE 5: LEFT SIDE BRACKET REMOVALS [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 7 8
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FIGURE 6: RIGHT SIDE BRACKET REMOVALS [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 8 2
FIGURE 7: STIFFENER REMOVAL - LBL 6.15 [Group 1, Configuration 1, 3] .............. 8 7
FIGURE 8: STIFFENER REMOVAL - LBL 6.15 [Group 3, Configuration 1, 3; Group 5, Configuration 1, 3]
.................................................. 8 9
FIGURE 9: STIFFENER REMOVAL - LBL 6.15 [Group 4, Configuration 1, 3] .............. 9 1
FIGURE 10: STIFFENER REMOVAL - LBL 6.15 [Group 6, Configuration 1, 3; Group 7, Configuration 1, 3;
Group 8, Configuration 1, 3] .................................. 9 3
FIGURE 11: GUSSET AND GROMMET REMOVAL - LBL 6.15 [Group 1, Configuration 1, 3; Group 3,
Configuration 1, 3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3; Group 6,
Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] . 95
FIGURE 12: NUTPLATE INSTALLATION - LBL 6.15 [Group 1, Configuration 1, 3; Group 3, Configuration 1,
3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] ................. 9 7
FIGURE 13: HOLE LOCATIONS AND GROUND STUD INSTALLATION - LBL 6.15 [Group 6, Configuration
1 ,  3 ,  5 - 6 ]  ............................................ 1 0 0
FIGURE 14: HOLE LOCATIONS AND GROUND STUD INSTALLATION - LBL 6.15 [Group 7, Configuration
1 ,  3 ,  5 - 6 ]  ............................................ 1 0 3
FIGURE 15: HOLE LOCATIONS AND GROUND STUD INSTALLATION - LBL 6.15 [Group 8, Configuration
1 ,  3 ,  5 - 6 ]  ............................................ 1 0 6
FIGURE 16: STIFFENER PRE-INSTALLATION - LBL 6.15 [Group 1, Configuration 1, 3] ....... 1 0 9
FIGURE 17: STIFFENER PRE-INSTALLATION - LBL 6.15 [Group 3, Configuration 1, 3; Group 5, Configuration
1 ,  3 ]  .............................................. 1 1 2
FIGURE 18: STIFFENER PRE-INSTALLATION - LBL 6.15 [Group 4, Configuration 1, 3] ....... 1 1 5
FIGURE 19: STIFFENER PRE-INSTALLATION - LBL 6.15 [Group 6, Configuration 1, 3; Group 7, Configuration
1, 3; Group 8, Configuration 1, 3] ............................... 1 1 8
FIGURE 20: STIFFENER INSTALLATION - LBL 6.15 [Group 1, Configuration 1, 3] .......... 1 2 1
F I G U R E  2 1 : T H I S  F I G U R E  I S  D E L E T E D ................................. 1 2 4
FIGURE 22: STIFFENER INSTALLATION - LBL 6.15 [Group 3, Configuration 1, 3; Group 5, Configuration
1 ,  3 ]  .............................................. 1 2 5
FIGURE 23: STIFFENER INSTALLATION - LBL 6.15 [Group 4, Configuration 1, 3] .......... 1 2 8
FIGURE 24: STIFFENER INSTALLATION - LBL 6.15 [Group 6, Configuration 1, 3; Group 7, Configuration
1, 3; Group 8, Configuration 1, 3] ............................... 1 3 1
FIGURE 25: GUSSET AND GROMMET INSTALLATION - LBL 6.15 [Group 1, Configuration 1, 3; Group 3,
Configuration 1, 3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3; Group 6,
Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] . 134
FIGURE 26: STIFFENER REMOVAL - RBL 6.15 [Group 1, Configuration 1, 3] ............. 1 3 7
FIGURE 27: STIFFENER REMOVAL - RBL 6.15 [Group 3, Configuration 1, 3] ............. 1 3 9
FIGURE 28: STIFFENER REMOVAL - RBL 6.15 [Group 4, Configuration 1, 3] ............. 1 4 1
FIGURE 29: STIFFENER REMOVAL - RBL 6.15 [Group 5, Configuration 1, 3] ............. 1 4 3
FIGURE 30: STIFFENER REMOVAL - RBL 6.15 [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 1 4 5
FIGURE 31: GUSSET REMOVAL - RBL 6.15 [Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group
4, Configuration 1, 3; Group 5, Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7,
Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .................. 1 4 7
FIGURE 32: HOLE LOCATIONS AND GROUND STUD INSTALLATION - RBL 6.15 [Group 1, Configuration
1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] . 149
FIGURE 33: HOLE LOCATIONS - RBL 6.15 [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3,
5-6; Group 8, Configuration 1, 3, 5-6] ............................ 1 5 1
FIGURE 34: STIFFENER PRE-INSTALLATION - RBL 6.15 [Group 1, Configuration 1, 3] ....... 1 5 3
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FIGURE 35: STIFFENER PRE-INSTALLATION - RBL 6.15 [Group 3, Configuration 1, 3] ....... 1 5 6
FIGURE 36: STIFFENER PRE-INSTALLATION - RBL 6.15 [Group 4, Configuration 1, 3] ....... 1 5 9
FIGURE 37: STIFFENER PRE-INSTALLATION - RBL 6.15 [Group 5, Configuration 1, 3] ....... 1 6 2
FIGURE 38: STIFFENER PRE-INSTALLATION - RBL 6.15 [Group 6, Configuration 1, 3, 5-6; Group 7,
Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .................. 1 6 5
FIGURE 39: STIFFENER INSTALLATION - RBL 6.15 [Group 1, Configuration 1, 3] .......... 1 6 8
F I G U R E  4 0 : T H I S  F I G U R E  I S  D E L E T E D ................................. 1 7 1
FIGURE 41: STIFFENER INSTALLATION - RBL 6.15 [Group 3, Configuration 1, 3] .......... 1 7 2
FIGURE 42: STIFFENER INSTALLATION - RBL 6.15 [Group 4, Configuration 1, 3] .......... 1 7 5
FIGURE 43: STIFFENER INSTALLATION - RBL 6.15 [Group 5, Configuration 1, 3] .......... 1 7 8
FIGURE 44: STIFFENER INSTALLATION - RBL 6.15 [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 1 8 1
FIGURE 45: GUSSET INSTALLATION - RBL 6.15 [Group 1, Configuration 1, 3; Group 3, Configuration 1,
3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3; Group 6, Configuration 1, 3, 5-6;
Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] ............. 1 8 4
FIGURE 46: LEFT SIDE BRACKET INSTALLATIONS [Group 1, Configuration 1, 3; Group 3, Configuration
1, 3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] ............... 1 8 7
FIGURE 47: RIGHT SIDE BRACKET INSTALLATIONS [Group 1, Configuration 1, 3; Group 3, Configuration
1, 3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] ............... 1 9 1
FIGURE 48: ANGLE INSTALLATION [Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4,
Configuration 1, 3; Group 5, Configuration 1, 3; Group 6, Configuration 1, 3; Group 7,
Configuration 1, 3; Group 8, Configuration 1, 3] ....................... 1 9 7
FIGURE 49: LEFT SIDE BRACKET INSTALLATIONS [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 2 0 0
FIGURE 50: RIGHT SIDE BRACKET INSTALLATIONS [Group 6, Configuration 1, 3, 5-6; Group 7,
Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .................. 2 0 4
FIGURE 51: SEALANT AND PAINT APPLICATION [Group 1, Configuration 1, 3; Group 3, Configuration 1,
3; Group 4, Configuration 1, 3; Group 5, Configuration 1, 3] ................ 2 1 0
FIGURE 52: SEALANT AND PAINT APPLICATION [Group 6, Configuration 1, 3, 5-6; Group 7, Configuration
1, 3, 5-6; Group 8, Configuration 1, 3, 5-6] .......................... 2 1 2
FIGURE 53: GROUNDING FASTENER INSTALLATION [Group 1, 3-8, Configuration 2] ....... 2 1 4
FIGURE 54: GROUND BRACKET INSTALLATION [Group 1, Configuration 1-3; Group 3, Configuration 1-3;
Group 4, Configuration 1-3; Group 5, Configuration 1-3; Group 6, Configuration 1-3, 5-6; Group
7, Configuration 1-3, 5-6; Group 8, Configuration 1-3, 5-6] ................. 2 1 6
FIGURE 55: BONDING JUMPER INSTALLATION [Group 1, Configuration 1-3; Group 3, Configuration 1-3;
Group 4, Configuration 1-3; Group 5, Configuration 1-3; Group 6, Configuration 1-3, 5-6; Group
7, Configuration 1-3, 5-6; Group 8, Configuration 1-3, 5-6] ................. 2 1 8
FIGURE 56: APPLICATION OF SEALANT ON FASTENERS COMMON TO STIFFENERS [Group 1,
Configuration 2] ........................................ 2 2 2
FIGURE 57: APPLICATION OF SEALANT ON FASTENERS COMMON TO STIFFENERS [Group 3,
Configuration 2] ........................................ 2 2 4
FIGURE 58: APPLICATION OF SEALANT ON FASTENERS COMMON TO STIFFENERS [Group 4-5,
Configuration 2] ........................................ 2 2 6
FIGURE 59: APPLICATION OF SEALANT TO FASTENERS ON STIFFENERS [Group 6-8, Configuration 2]
................................................. 2 2 8
FIGURE 60: STIFFENER REMOVAL - LBL 6.15 [Group 6, Configuration 5-6; Group 7, Configuration 5-6;
Group 8, Configuration 5-6] .................................. 2 3 0
FIGURE 61: STIFFENER PRE-INSTALLATION - LBL 6.15 [Group 6, Configuration 5-6; Group 7, Configuration
5-6; Group 8, Configuration 5-6] ............................... 2 3 2
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FIGURE 62: STIFFENER INSTALLATION - LBL 6.15 [Group 6, Configuration 5-6; Group 7, Configuration
5-6; Group 8, Configuration 5-6] ............................... 2 3 5
FIGURE 63: ANGLE INSTALLATION [Group 6, Configuration 5-6; Group 7, Configuration 5-6; Group 8,
Configuration 5-6] ....................................... 2 3 8
APPENDIX A: PART DEMAND INTENT ................................... 2 4 1
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Commercial 
Airplanes
737
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 737-57A1269Original Issue: December 04, 2003
Revision 2: October 11, 2018
ATA System: 5712
SUBJECT: WINGS - Wing Center Section Rear Spar - Replacement of Stiffeners at Left and Right
BBL 6.15
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-20-01 is related to this service bulletin.
The effective date of AD 2005-20-01 is November 01, 2005.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-10-12 is related to this service bulletin.
The effective date of AD 2018-10-12 is June 07, 2018.
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.
Effects of this Revision on airplanes on which the Original Issue or Revision 1 was previously done:
See Paragraph 1.D., Description for more information.
Airplanes with line numbers 1-291 were moved from Groups 1, 3, 4, and 5 and moved into Group 2. Group 2
now contains all 737-100/200/200C airplanes with line numbers 1-291. These airplanes are beyond the Limit
of Validity (LOV).
REASON FOR REVISION
This revision is sent to remove the stiffener inspection requirement, which is given in Boeing Service Bulletin
737-57A1339. In addition, this revision is sent to give compliance time for the stiffener replacement, to give
instructions to install different fasteners for the stiffener replacement, and to add new bonding jumpers to restore
fault current bonding path.
The data given in Information Notices 737-57A1269 IN 01, IN 02, IN 03 and IN 04 are included in this revision.
Terminology defined in Paragraph 3.A., General Information - Notes, only applies to the Accomplishment
Instructions added in Revision 2 of this Service Bulletin.
These sections were changed:
1. In Subject, changed the description due to removal of the inspection requirement.
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2. In Summary, Concurrent Requirements, added a sentence referring to Paragraph 1.B., Concurrent
Requirements.
3. In Summary, Background, updated new background information and added references to related
documents.
4. In Summary, Action, updated to give stiffener replacement information with applicable
group-configuration.
5. In Summary, Effectivity, added a sentence referring to Paragraph 1.A.1., Airplanes.
6. In Summary, Compliance, updated to give information related to Airworthiness Directives.
7. In Summary Manpower, changed information to include a reference to Paragraph 1.G., Manpower.
8. In Summary, Material Information, added information to include reference to APPENDIX A, Operator
Supplied Parts/Materials and Paragraph 2.A., Material - Price and Availability.
9. In Summary Illustration, changed summary text.
10. In Paragraph 1.A.1, Effectivity, created new configurations for Groups 1, 3-8 for airplanes that have
done previous replacements of stiffeners, added nitrogen generation systems, or done other repairs.
Changed Group 2 to cover airplanes beyond Limit of Validity.
11. In Paragraph 1.B., Concurrent Requirements, added a new requirement.
12. In Paragraph 1.C., Reason, updated new background information, added references to related
documents, and added reason for this revision.
13. In Paragraph 1.D., Description, updated to give stiffener replacement information with applicable
group-configuration due to changes in the compliance information, added effects of this revision
information, and added Affected Maintenance Zones tables
14. In Paragraph 1.E., Compliance, updated to give information related to Airworthiness Directives. Added
new compliance information related to stiffener replacement and restoring fault current bonding path
with applicable group-configuration information.
15. In Paragraph 1.F., Approval, added paragraphs for Alternate Method of Compliance approval, statement
of applicability to EASA/JAA Aircraft and statement for AWL.
16. In Paragraph 1.G., Manpower, updated and added manpower tables to reflect new and changed
configurations.
17. In Paragraph 1.H., Weight and Balance Changes, updated the table.
18. In Paragraph 1.J.1., Existing Data, updated the reference list.
19. In Paragraph 1.K., Publications Affected, added information for Damage Tolerance Inspections.
20. In Paragraph 1.L., Interchangeability and Intermixability of Parts: Updated statement.
21. In Paragraph 2.A., Material - Price and Availability, changed tables to reflect new kits.
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22. In Paragraph 2.C.1., Kits/Parts, changed parts tables to reflect new kits and added statements to clarify
kits.
23. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, updated the parts list.
24. In Paragraph 3.A., General Information, added notes.
25. In Paragraph 3.B., Work Instructions,
a. Added information for airplanes beyond the Limit of Validity and airplanes that do not require further
action.
b. Updated group-configuration information throughout the work instructions.
c. Renumbered affected PART due to installation of the bonding jumper instructions.
d. PART I - deleted information.
e. PART II - added step to remove the time limited repair.
f. PART III - added a caution note and step to remove the time limited repair.
g. PART IV and PART V - removed references to Group 2 airplanes.
h. PART VI and PART VII - changed the PART description and moved the angle installation to PART
VIII.
i. Added PART VIII to give installation of angle and bonding jumpers.
j. PART IX - updated close access information with applicable group-configuration information.
k. Added PART XI through PART XIII to give instructions for more work on airplane that have replaced
the stiffeners.
26. Figure 1 - deleted information.
27. In Figures 2, 3, and 6, updated illustration.
28. In Figures 7, 8, 9, 10, 11, 26, 27, 28, 29, 30, 31, updated footnote (a).
29. In Figure 12, updated a part number.
30. In Figures 13, 14, 15, 32 and 33, added a note reflecting that bonding stud placement being reference
only.
31. In Figures 16, 17, 18, 19, 34, 35, 36, 37 and 38, added fastener codes for grounding fasteners, updated
hole diameters due to updated A-code fasteners and updated illustrations.
32. In Figures 20, 22, 23, 24, 39, 41, 42, 43 and 44, added fastener codes for grounding fasteners, updated
A-code fasteners, and added instructions to apply sealant to fasteners inside the fuel tank.
33. Removed Figures 21 and 40 related to Group 2 airplanes.
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34. In Figures 25 and 45, updated fasteners.
35. In Figures 46, 47, and 48, updated illustrations and fastener information.
36. In Figures 49 and 50, updated fastener information.
37. In Figure 51, updated application of sealant step.
38. In Figures 52, updated illustration and application of sealant step.
39. Added Figures 53 to give instructions for grounding fasteners installation on airplanes which have
replaced stiffeners.
40. Added Figure 54 to provide instructions for installing a ground bracket.
41. Added Figure 55 to provide instructions for installing bonding jumpers.
42. Added Figures 56, 57, 58, and 59, to give instructions to apply sealant to fasteners inside the fuel tank
on airplanes which have replaced stiffeners.
43. Added Figures 60, 61, and 62, to give instructions for stiffener replacement to address a different
configuration.
44. Added Figure 63, to give instructions for angle installation to address a different configuration.
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
December 04, 2003Original Issue:
September 16, 2004Revision 1:
October 11, 2018Revision 2:
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Commercial 
Airplanes
737
Service Bulletin
ALERT
SummaryNumber: 737-57A1269Original Issue: December 04, 2003
Revision 2: October 11, 2018
ATA System: 5712
SUBJECT: WINGS - Wing Center Section Rear Spar - Replacement of Stiffeners at Left and Right
BBL 6.15
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
Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND
This service bulletin gives the instructions to replace the stiffeners at Left Buttock Line (LBL) 6.15 and Right
Buttock Line (RBL) 6.15 on the rear spar of the wing center section.
Boeing has reports of cracks in the stiffeners at LBL 6.15 and RBL 6.15 on the wing center section rear spar.
One of the reports show that a crack was fully through the stiffener at RBL 6.15, just below the lower spar chord
on a 737-200 airplane. Other reports show that cracks were found in these stiffeners on seven 737-300 airplanes.
On two of the 737-300 airplanes the cracks were fully through the stiffeners at LBL and RBL 6.15, and damage
was also found on the keel beam structure.
The 737-200 airplane had 39,383 flight hours and 40,888 flight cycles. The 737-300 airplanes had 39,821 to
52,139 flight hours, and 20,697 to 47,496 flight cycles.
Continued operation with cracks in the stiffeners could cause damage to the keel beam structure. Damage,
sufficient to reduce the load capability of the keel beam structure, could be one result.
The new improved stiffeners are made from 2024-T351 aluminum alloy plate and replace the stiffeners made
from 7075-T6511 aluminum extrusion. The new stiffeners have increased flange thickness and also have two
flanges for attachment to the center section rear spar, as compared to the existing stiffeners that have one flange
for attachment to the spar. The new stiffener configuration gives the strength necessary to prevent cracks at
LBL and RBL 6.15 on the wing center section rear spar.
After the release of Revision 1 of this service bulletin, Boeing has found that the replacement stiffener installation
had degraded fault current bonding because it replaced the existing rivets (which provide an inherent bond path
for fault currents and ground returns) with non-conductive finish K-code fasteners in transition fit holes. The
replacement fasteners are not adequate in maintaining required fault current bonding path and thus, do not
satisfy Special Federal Aviation Regulation (SFAR) 88 requirements. This revision is sent to update the instructions
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### Page 12

for airplanes that have not previously replaced their stiffeners and also to provide instructions for restoring the
fault current bonding on airplanes that have previously replaced the stiffeners. The fault current bonding will be
restored through strategic replacement of K-coded fasteners with A-coded (cadmium plated steel) fasteners in
interference fit holes. In addition, four electrical bonding jumpers will be installed to maintain adequate fault
current bonding between the hydraulic pumps and the web structure.
In addition to the above described electrical bonding issues, Boeing has received a report of cracks in the left
side and right side keel beam upper chords when replacing the aft vertical stiffeners. Boeing has determined
that the actual stresses on aft vertical stiffeners at LBL and RBL 6.15 are more than those used to design the
structure and can cause fatigue cracks in the stiffeners. If the aft vertical stiffeners have cracks or are severed,
the fatigue damage may extend into the adjacent keel beam structure and could reduce the limit load capability
of the keel beam structure. Boeing has determined the inspections given in the Original Issue and Revision 1
of this service bulletin do not provide sufficient inspection intervals for timely crack detection in the aft vertical
stiffeners. As a result, Boeing has issued Service Bulletin 737-57A1339 to inspect the stiffeners and keel beam
upper chord structures.
Accomplishment of the Stiffener Replacements at LBL 6.15 and RBL 6.15 given in this service bulletin terminates
the inspection requirements in accordance with Boeing Service Bulletin 737-57A1339.
Airworthiness Limitation (AWL) 28-AWL-11 listed in the Certification Maintenance Requirements (CMRs)
document, D6-38278-CMR, is related to this service bulletin.
Boeing Structural Item Interim Advisory (SIIA) 737-273 is related to this service bulletin.
Boeing Service Related Problems (SRP) 737-SRP-57-0135, 737-SRP-57-0293, and 737-SRP-57-0343 are
related to this service bulletin.
ACTION (PRR 35005-239RS)
Group 2:
The Boeing Company 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, The Boeing Company no longer provides maintenance instructions for airplanes
that have accumulated flight cycles beyond the LOV. Airplanes in Group 2 (line number 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 1, 3-8, Configuration 4:
No further action required.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
Get access. Replace the stiffeners at LBL 6.15 and RBL 6.15 on the wing center section rear spar with the new
improved stiffeners and do the installation of angle and bonding jumpers and close access.
Group 1, 3-8, Configuration 2:
Get access and do the installation of bonding fasteners and bonding jumpers, and sealing of fasteners and close
access.
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### Page 13

EFFECTIVITY
All 737-100/-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected
airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-20-01 is related to this service bulletin.
The effective date of AD 2005-20-01 is November 01, 2005.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-10-12 is related to this service bulletin.
The effective date of AD 2018-10-12 is June 07, 2018.
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.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to help Boeing
predict the quantity and timing of the Boeing Supplied Kits/Parts.
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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### Page 14 (OCR)

BOEING SERVICE BULLETIN 737-57A1269
ALERT  ALERT
RBL
24.92
RBL
6.15
LBL
LBL  6.15
24.92
REAR SPAR
STA
663
CRACK
EXAMPLE  * CRACK
EXAMPLE
• STIFFENER
WL
170.4
STIFFENER
REPLACE THE STIFFENERS WITH
NEW STRONGER STIFFENERS.  DO
THE INSTALLATION OF ANGLE AND
BONDING JUMPERS.
2527213
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### Page 15

Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-57A1269
Original Issue: December 04, 2003
Revision 2: October 11, 2018
ATA System: 5712
SUBJECT: WINGS - Wing Center Section Rear Spar - Replacement of Stiffeners at Left and Right
BBL 6.15
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) 1-3132 in 8 Group(s).
The Variable Numbers and Group Information for the applicable airplanes is given below. Refer
to PRR35005-239RS and PRR35005-319RS for data about this change.
Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
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### Page 16

DESCRIPTIONCONFIGURATIONGROUP
737-200/-200C airplanes with a tank lacing anchor and two eyebolts,
and that use longer grip length fasteners for the installation of the
stiffeners than some of the other 737-200/-200C airplanes.
-1
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and have not
installed the time-limited repair LOR-760.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and that have
installed the time-limited repair LOR-760.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
737-100/-200/-200C airplanes, line numbers 1 - 291.-2
737-200 airplanes with a tank lacing anchor and one eyebolt, and
that have a different fastener pattern for the installation of the
stiffeners than the other 737-200 airplanes.
-3
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and have not
installed the time-limited repair LOR-760.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and that have
installed the time-limited repair LOR-760.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
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ALERTALERT

### Page 17

DESCRIPTIONCONFIGURATIONGROUP
737-200/-200C airplanes without tank lacing anchors and eyebolts,
and that use longer grip length fasteners for the installation of the
stiffeners than some of the other 737-200/-200C airplanes.
-4
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and have not
installed the time-limited repair LOR-760.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and that have
installed the time-limited repair LOR-760.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
737-200 airplanes without tank lacing anchors and eyebolts, and that
have a different fastener pattern for the installation of the stiffeners
than the other 737-200 airplanes.
-5
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and have not
installed the time-limited repair LOR-760.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed) and that have
installed the time-limited repair LOR-760.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions..
4
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### Page 18

DESCRIPTIONCONFIGURATIONGROUP
737-300 airplanes that have ground stud and hole locations in the
stiffeners that are different from the other airplanes.
-6
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed),have not installed
time-limited repair LOR-760, and have not accomplished Boeing SB
737-47-1007.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have installed
the time-limited repair LOR-760, and have not accomplished Boeing
SB 737-47-1007.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have installed
the time-limited repair LOR-760, and have accomplished Boeing SB
737-47-1007.
5
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have not installed
the time-limited repair LOR-760, and have accomplished Boeing SB
737-47-1007.
6
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ALERTALERT

### Page 19

DESCRIPTIONCONFIGURATIONGROUP
737-300 airplanes that have ground stud and hole locations in the
stiffeners that are different from the other airplanes.
-7
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed). have not installed
the time-limited repair LOR-760, and have not accomplished Boeing
SB 737-47-1007.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have installed
the time-limited repair LOR-760, and have not accomplished Boeing
SB 737-47-1007.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmuim-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production fasteners installed), have installed
the time-limited repair LOR-760, and have accomplished Boeing SB
737-47-1007.
5
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production fasteners installed), and have not
installed the time-limited repair LOR-760, and have accomplished
Boeing SB 737-47-1007.
6
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ALERTALERT

### Page 20

DESCRIPTIONCONFIGURATIONGROUP
737-300/-400/-500 airplanes that have ground stud and hole locations
in the stiffeners that are different from the other airplanes.
-8
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have not installed
the time-limited repair LOR-760, and have not accomplished Boeing
SB 737-47-1004 or Boeing SB 737-47-1007.
1
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this Service Bulletin.
2
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), and have installed
the time-limited repair LOR-760, and have not accomplished Boeing
SB 737-47-1004 or Boeing SB 737-47-1007.
3
Airplanes that have replaced the stiffeners in accordance with the
Original Issue or Revision 1 of this service bulletin but installed
cadmium-plated steel fasteners in interference-fit holes in accordance
with Boeing Instructions.
4
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have installed
the time-limited repair LOR-760, and have accomplished Boeing SB
737-47-1004 or Boeing SB 737-47-1007.
5
Airplanes that have not replaced the stiffeners in accordance with
this service bulletin (production stiffeners installed), have not installed
the time-limited repair LOR-760, and have accomplished Boeing SB
737-47-1004 or Boeing SB 737-47-1007.
6
Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500
GroupVariable Number
2PA001 - PA022
2PA099
2PA231 - PA232
2PC001 - PC005
2PG001 - PG075
2PG199
2PG201 - PG230
2PG251 - PG255
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### Page 21

GroupVariable Number
2PG271 - PG279
2PG301 - PG314
2PG331 - PG332
2PG351 - PG356
2PG375
2PG401 - PG403
2PG431 - PG442
2PG471 - PG475
2PG501 - PG505
2PG571 - PG583
3PG584 - PG586
2PG621 - PG630
2PG651 - PG652
2PG701 - PG705
3PH001
5PH011 - PH013
5PH021 - PH024
2PH701 - PH715
2PH731 - PH732
2PH741 - PH742
5PH743
2PJ001 - PJ002
4PJ003 - PJ009
2PJ031 - PJ032
2PJ071 - PJ072
2PJ101 - PJ104
4PJ105 - PJ119
4PJ201 - PJ219
8PJ301 - PJ302
8PJ551 - PJ561
8PJ601 - PJ615
8PJ811
8PJ816 - PJ817
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### Page 22

GroupVariable Number
4PK026 - PK029
4PK041 - PK053
4PK061 - PK070
4PK081 - PK082
4PK091 - PK099
4PK101 - PK103
4PK111 - PK120
4PK141 - PK146
4PK201 - PK204
4PK211 - PK223
4PK231 - PK241
4PK251 - PK258
4PK271 - PK274
4PK281 - PK289
4PK291
4PK301 - PK318
4PK341
4PK351 - PK361
4PK391
4PK431 - PK433
4PK451 - PK452
4PK461 - PK469
4PK495
4PK501 - PK504
4PK511 - PK515
4PK519
4PK521 - PK528
4PK541 - PK565
4PK581
4PK591 - PK599
4PK601 - PK617
4PK621 - PK637
4PK641 - PK642
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### Page 23

GroupVariable Number
4PK661 - PK666
4PK671 - PK681
4PK691 - PK697
4PK711 - PK716
4PK731 - PK765
4PK771 - PK779
4PK801 - PK804
4PK819 - PK827
4PK830
4PK861 - PK863
4PK871 - PK874
4PK881 - PK884
4PK901 - PK938
4PK971 - PK974
4PL001 - PL028
4PL061
4PL081
4PL101 - PL113
4PL151
4PL171 - PL172
4PL201 - PL203
4PL221
4PL401 - PL417
4PL421
4PL441
4PL451 - PL456
4PL471
4PL491
4PL501 - PL506
4PL551 - PL562
4PL581
4PL601 - PL603
4PL611
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### Page 24

GroupVariable Number
4PL621 - PL626
4PL631 - PL632
2PL711 - PL712
2PL716
4PL717 - PL725
1PL726 - PL728
4PL729 - PL735
1PL736 - PL742
4PL743 - PL747
1PL756
4PL758
1PL761
4PL762 - PL770
4PL781 - PL788
4PL793
2PL801 - PL803
4PM001 - PM006
4PM016 - PM017
4PM021 - PM023
4PM051 - PM066
4PM101 - PM119
4PM141 - PM142
4PM171
4PM181
4PM251 - PM255
4PM281 - PM283
8PM381 - PM399
8PM401 - PM417
8PM541 - PM564
4PN001 - PN002
4PN021 - PN043
4PN081 - PN086
4PN101 - PN117
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### Page 25

GroupVariable Number
4PN131 - PN163
4PN401 - PN420
4PN431 - PN433
4PN451 - PN456
4PN471 - PN474
4PN481
4PN491 - PN493
4PN501 - PN502
4PN511 - PN512
4PN521
6PP001 - PP005
7PP006 - PP031
8PP032
7PP033 - PP047
8PP048 - PP054
7PP101 - PP126
8PP127 - PP160
7PP161 - PP168
8PP169
7PP181 - PP184
8PP185 - PP199
7PP201 - PP204
8PP205
7PP221
7PP231 - PP243
7PP281 - PP286
7PP301 - PP305
7PP351 - PP352
8PP353
7PP376 - PP384
8PP391 - PP393
7PP401 - PP424
8PP425 - PP440
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### Page 26

GroupVariable Number
7PP471 - PP475
7PP501 - PP504
8PP505 - PP520
7PP521 - PP522
7PP631 - PP634
7PP651 - PP652
7PP671 - PP699
7PP701 - PP720
8PP721 - PP733
7PP771 - PP777
8PP778 - PP779
7PP801 - PP804
8PP805 - PP808
7PP821 - PP827
7PP831 - PP836
8PP837 - PP845
7PP846 - PP848
7PP851
8PP852
7PP861 - PP870
8PP871 - PP877
7PP891 - PP899
7PP901 - PP905
8PP906 - PP930
7PP931 - PP934
8PP935 - PP936
7PP946 - PP948
8PP951 - PP952
7PP961 - PP965
8PP966 - PP967
7PP981 - PP982
8PP983 - PP990
7PP991
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### Page 27

GroupVariable Number
8PP993
7PQ001 - PQ012
8PQ013 - PQ016
7PQ026 - PQ037
8PQ038 - PQ041
7PQ051 - PQ062
8PQ063 - PQ085
7PQ086
8PQ087 - PQ092
7PQ101 - PQ110
8PQ111 - PQ199
8PQ201 - PQ202
8PQ221 - PQ237
8PQ241 - PQ243
8PQ251 - PQ267
8PQ281 - PQ299
8PQ301 - PQ307
8PQ331 - PQ332
8PQ341 - PQ348
8PQ361 - PQ373
8PQ391 - PQ395
8PQ401 - PQ418
8PQ421
8PQ431 - PQ438
8PQ447 - PQ448
8PQ451
8PQ454
8PQ471 - PQ475
8PQ479 - PQ481
8PQ486 - PQ487
8PQ491 - PQ493
8PQ771 - PQ772
8PQ791 - PQ793
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### Page 28

GroupVariable Number
8PQ801 - PQ805
8PQ931 - PQ935
8PQ951
8PQ971 - PQ997
8PR001 - PR017
8PR021 - PR034
8PR041 - PR045
8PR061 - PR072
8PR077 - PR082
8PR091 - PR092
8PR096
8PR101
8PR121 - PR122
8PR131 - PR132
8PR141 - PR143
8PR161 - PR172
8PR181
8PS601 - PS631
8PS636 - PS638
8PS641 - PS644
8PS651 - PS657
8PS666 - PS669
8PS691 - PS692
8PS701 - PS706
8PS751 - PS799
8PS811
8PS836 - PS837
8PS841 - PS846
8PS851 - PS852
8PS856
8PS861 - PS863
8PS866 - PS868
8PS871 - PS874
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### Page 29

GroupVariable Number
8PS896 - PS897
8PS901 - PS941
8PS956 - PS957
8PS961 - PS963
8PS971 - PS978
8PT001 - PT015
8PT021 - PT031
8PT041 - PT064
8PT101 - PT105
8PT121 - PT138
8PT146 - PT148
8PT161 - PT170
8PT181 - PT188
8PT211 - PT220
8PT295
8PT301 - PT309
8PT331 - PT360
8PT381 - PT399
8PT401 - PT438
8PT501 - PT517
8PT561 - PT565
8PT581 - PT586
8PT611 - PT621
8PT641 - PT644
8PT651 - PT656
8PT671 - PT672
8PT681 - PT685
8PT701 - PT703
8PT716 - PT717
8PT721 - PT725
8PT801 - PT834
8PT851 - PT854
8PT871 - PT886
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### Page 30

GroupVariable Number
8PT901 - PT930
8PT971 - PT973
8PT981 - PT985
8PT996
8PU001 - PU025
8PU301
8PU311 - PU313
8PV001 - PV055
8PV201 - PV209
8PV226 - PV229
8PV231 - PV237
8PV271 - PV272
8PV281 - PV287
8PV296
8PV301 - PV302
8PV351
8PV356 - PV357
8PW001 - PW054
8PW061 - PW068
8PW072
8PW086 - PW088
8PW091 - PW094
8PW101 - PW102
8PW106
8PW111 - PW120
8PW156 - PW157
8PW161 - PW171
8PW201 - PW252
8PW261 - PW268
8PW271 - PW276
8PW278
8PW281 - PW293
8PW296
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GroupVariable Number
8PW301 - PW327
8PW401 - PW408
8PW411 - PW418
8PW421 - PW424
8PW431 - PW435
8PW441 - PW450
8PW461 - PW467
8PW501 - PW504
8PW511 - PW522
8PW524 - PW550
8PW556 - PW557
8PW561 - PW564
8PW571 - PW576
8PW591 - PW596
8PW611 - PW622
8PW631 - PW637
8PW661 - PW662
8PW681 - PW683
8PW701 - PW702
8PW711 - PW717
8PW741 - PW742
8PW761
8PW771
8PW831
8PW851 - PW856
2PX071
2PX701
2PY001 - PY008
2PY021
4PY022
2PY031
1PY036 - PY037
1PY046 - PY047
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GroupVariable Number
4PY048
4PY051 - PY053
4PY056 - PY057
4PY101 - PY103
4PY111 - PY113
4PY131 - PY135
4PY141 - PY143
4PY151 - PY154
4PY156 - PY157
4PY161 - PY162
4PY166
4PY191
4PY201
4PY221 - PY222
4PY231
4PY241 - PY244
4PY270 - PY275
4PY281
4PY286
2PY301 - PY304
2PY321 - PY323
2PY341 - PY346
2PY361 - PY362
2PY381
4PY401
4PY409 - PY411
4PY421 - PY422
4PY441
4PY451
4PY461 - PY463
4PY591 - PY595
4PY611 - PY612
4PY621
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GroupVariable Number
4PY631
4PY651
4PY671 - PY672
4PY721
4PY741
2. Spares Affected
None.
B. Concurrent Requirements
The document(s) listed below must be done at the same time as this service bulletin:
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5, Configu-
ration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1,
3, 5-6:
DescriptionDocumentCompany
A final one-time Surface HFEC Inspection
of the Keel Beam Upper Chord and General
Visual Inspection of the Angle at LBL 6.50
and RBL 6.50 and all related applicable ac-
tions.
Requirements Bulletin 737-57A1339 RB,
Original Issue
The Boeing Compa-
ny
Group 1, Configuration 2, 4; Group 2; Group 3, Configuration 2, 4; Group 4, Configuration 2, 4;
Group 5, Configuration 2, 4; Group 6, Configuration 2, 4; Group 7, Configuration 2, 4; Group 8,
Configuration 2, 4:
None.
C. Reason
This service bulletin gives the instructions to inspect, and if necessary, replace the stiffeners at Left
Buttock Line (LBL) 6.15 and Right Buttock Line (RBL) 6.15 on the rear spar of the wing center section.
Boeing has reports of cracks in the stiffeners at LBL 6.15 and RBL 6.15 on the wing center section rear
spar. One of the reports show that a crack was fully through the stiffener at RBL 6.15, just below the
lower spar chord on a 737-200 airplane. Other reports show that cracks were found in these stiffeners
on seven 737-300 airplanes. On two of the 737-300 airplanes the cracks were fully through the stiffeners
at LBL and RBL 6.15, and damage was also found on the keel beam structure.
The 737-200 airplane had 39,383 flight hours and 40,888 flight cycles. The 737-300 airplanes had
39,821 to 52,139 flight hours, and 20,697 to 47,496 flight cycles.
Continued operation with cracks in the stiffeners could cause damage to the keel beam structure.
Damage, sufficient to reduce the load capability of the keel beam structure, could be one result.
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The new improved stiffeners are made from 2024-T351 aluminum alloy plate and replace the stiffeners
made from 7075-T6511 aluminum extrusion. The new stiffeners have increased flange thickness and
also have two flanges for attachment to the center section rear spar, as compared to the existing
stiffeners that have one flange for attachment to the spar. The new stiffener configuration gives the
strength necessary to prevent cracks at LBL and RBL 6.15 on the wing center section rear spar.
After the release of Revision 1 of this service bulletin, Boeing has found that the replacement stiffener
installation had degraded fault current bonding because it replaced the existing rivets (which provide
an inherent bond path for fault currents and ground returns) with non-conductive finish K-code fasteners
in transition fit holes. The replacement fasteners are not adequate in maintaining required fault current
bonding path and thus, do not satisfy Special Federal Aviation Regulation (SFAR) 88 requirements.
This revision is sent to update the instructions for airplanes that have not previously replaced their
stiffeners and also to provide instructions for restoring the fault current bonding on airplanes that have
previously replaced the stiffeners. The fault current bonding will be restored through strategic replacement
of K-coded fasteners with A-coded (cadmium plated steel) fasteners in interference fit holes. In addition,
four electrical bonding jumpers will be installed to maintain adequate fault current bonding between
the hydraulic pumps and the web structure.
In addition to the above described electrical bonding issues, Boeing has received a report of cracks in
the left side and right side keel beam upper chords when replacing the aft vertical stiffeners. Boeing
has determined that the actual stresses on aft vertical stiffeners at LBL and RBL 6.15 are more than
those used to design the structure and can cause fatigue cracks in the stiffeners. If the aft vertical
stiffeners have cracks or are severed, the fatigue damage may extend into the adjacent keel beam
structure and could reduce the limit load capability of the keel beam structure. Boeing has determined
the inspections given in the Original Issue and Revision 1 of this service bulletin do not provide sufficient
inspection intervals for timely crack detection in the aft vertical stiffeners. As a result, Boeing has issued
Service Bulletin 737-57A1339 to inspect the stiffeners and keel beam upper chord structures.
Accomplishment of the Stiffener Replacements at LBL 6.15 and RBL 6.15 given in this service bulletin
terminates the inspection requirements in accordance with Boeing Service Bulletin 737-57A1339.
Airworthiness Limitation (AWL) 28-AWL-11 listed in the Certification Maintenance Requirements (CMRs)
document, D6-38278-CMR, is related to this service bulletin.
Boeing Structural Item Interim Advisory (SIIA) 737-273 is related to this service bulletin.
Boeing Service Related Problems (SRP) 737-SRP-57-0135, 737-SRP-57-0293, and 737-SRP-57-0343
are related to this service bulletin.
Revision 1: Sent to add airplanes to the service bulletin effectivity, move airplanes into different groups,
and make corrections to typographical errors in the manual references.
Revision 2: Sent to remove the stiffener inspection requirement, which is given in Boeing Service
Bulletin 737-57A1339. In addition, this revision is sent to give compliance time for the stiffener
replacement, to give instructions to install different fasteners for the stiffener replacement, and to add
new bonding jumpers to restore fault current bonding path.
The data given in Information Notices 737-57A1269 IN 01, IN 02, IN 03 and IN 04 are included in this
revision.
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D. Description
Group 2:
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 2 (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 1, 3-8, Configuration 4:
No further action required.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
1. Do the work outlined below:
– Replacement - Remove fuel and get access to the center tank. Remove the fuel cell from
737-100/200 airplanes, if installed. Put the airplane on jacks. Remove the hydraulic pumps
and components to get access to the stiffeners at LBL 6.15 and RBL 6.15. Remove electrical
power and disconnect wires from the ground studs installed on the stiffeners. As necessary,
remove components of the air-conditioning and pneumatic systems form the left and right
pack bays to get access to the forward surface of the wheel well bulkhead at LBL 6.15 and
RBL 6.15.
– Remove the left and right support assemblies for the removed hydraulic pumps on the wheel
well bulkhead. Remove the angle between the left and right stiffeners and then remove the
stiffeners including the time-limited repair if installed. Remove the gusset and grommet from
the lower left side of the bulkhead. Use the removed stiffeners to get the hole, and ground
stud locations, on the new stiffeners. Put the new stiffeners in position, install and adjust the
shims, and drill the necessary holes. Clean and deburr the components and apply a chemical
treatment to bare aluminum as necessary. Apply sealant and install the new stiffeners. Install
the gusset and grommet on the lower left side of the bulkhead.
– Install the left and right support assemblies for the hydraulic pumps and install the angle
between the stiffeners. Install grounding bracket on the rear spar and bonding jumpers from
hydraulic pump support brackets to grounding bracket. Apply sealant and paint to the repair
area. Install the fuel cell on 737-100/200 airplanes, if removed. Put the electrical wires back
into position and connect the applicable wires to the ground studs installed on the new
stiffeners. Install the removed components of the air-conditioning and pneumatic systems.
Install the hydraulic pumps and components. Do a leak check of the hydraulic system.
– Put the airplane back to a serviceable condition.
Group 1, 3-8, Configuration 2:
Get access. Install the grounding fasteners, grounding bracket on the rear spar, and bonding jumpers
from hydraulic pump support brackets to grounding bracket and seal the fasteners in the fuel tank area
going through the stiffeners at LBL 6.15 and RBL 6.15 in the fuel tank area. Close access and put the
airplane back into a serviceable condition.
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The airplane effectivity is divided into eight (8) groups. Groups 1 and 3 thru 5 are 737-200 series
airplanes, and are in four groups because of differences between the fastener patterns and fastener
grip lengths. Group 2 is 737-100/200 series airplanes that are beyond the Limit of Validity. Groups 6
thru 8 are 737-300/400/500 series airplanes, and are in three groups because of differences between
the ground stud locations and hole locations for attachment of system components.
Effects of this Revision on airplanes on which the Original Issue or Revision 1 was previously done:
ActionConditionGroup
Do the Stiffener Replacements at
LBL 6.15 and RBL 6.15, and Instal-
lation of Angle and Bonding
Jumpers in accordance with PART
IV, PART V and PART VIII of Para-
graph 3.B., Work Instructions, at the
times specified in Paragraph 1.E.,
Compliance.
Airplanes that have not replaced the
stiffeners in accordance with this
service bulletin (production stiffeners
installed)
Group 1, 3-5, Configuration 1; Group
6-8, Configuration 1, 6
Do the Stiffener Replacements at
LBL 6.15 and RBL 6.15, and Instal-
lation of Angle and Bonding
Jumpers in accordance with PART
IV, PART V and PART VIII of Para-
graph 3.B., Work Instructions, at the
times specified in Paragraph 1.E.,
Compliance.
Airplanes that have not replaced the
stiffeners in accordance with this
service bulletin (production stiffeners
installed)
Group 1, 3-5, Configuration 3; Group
6-8, Configuration 3, 5
Do the Installation of Bonding Fas-
teners and Bonding Jumpers, and
Sealing of Fasteners in accordance
with PART XII of Paragraph 3.B.,
Work Instructions, at the times
specified in Paragraph 1.E., Compli-
ance.
Airplanes that have replaced the
stiffeners in accordance with the
Original Issue or Revision 1 of this
service bulletin
Group 1, 3-8, Configuration 2
No further action required.Airplanes that have replaced the
stiffeners in accordance with the
Original Issue or Revision 1 of this
service bulletin but installed cadmi-
um-plated steel fasteners in interfer-
ence-fit holes in accordance with
Boeing Instructions.
Group 1, 3-8, Configuration 4
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1, 4:
Affected Maintenance Zones
ZoneModel
2-11, 2-12, 2-13, 2-14, 2-15, 2-16, 2-17737-200, 737-200C
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Group 2:
Affected Maintenance Zones
ZoneModel
2-11, 2-12, 2-13, 2-14, 2-15, 2-16, 2-17737-100, 737-200, 737-200C
Group 3, 5:
Affected Maintenance Zones
ZoneModel
2-11, 2-12, 2-13, 2-14, 2-15, 2-16, 2-17737-200
Group 6-7:
Affected Maintenance Zones
ZoneModel
211, 212, 213, 214, 215, 216, 217737-300
Group 8:
Affected Maintenance Zones
ZoneModel
211, 212, 213, 214, 215, 216, 217737-300, 737-400, 737-500
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-20-01 is related to this service
bulletin. The effective date of AD 2005-20-01 is November 01, 2005.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-10-12 is related to this service
bulletin. The effective date of AD 2018-10-12 is June 07, 2018.
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.
Group 2:
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 2 (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 1, 3-8, Configuration 4:
No further action required.
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Group 1, 3-6, Configuration 1; Group 6, Configuration 6; Group 7, Configuration 1, 6; Group 8,
Configuration 1, 6:
Boeing recommends that the Stiffener Replacements at LBL 6.15 and RBL 6.15, and Installation of
Angle and Bonding Jumpers given in the service bulletin be done before 15,000 total flight cycles or
within 4,500 flight cycles after the Revision 2 date of this service bulletin, whichever occurs later.
Group 1, 3-6, Configuration 3; Group 6, Configuration 5; Group 7, Configuration 3, 5; Group 8,
Configuration 3, 5:
Boeing recommends that the Stiffener Replacements at LBL 6.15 and RBL 6.15, and Installation of
Angle and Bonding Jumpers given in the service bulletin be done within 15,000 flight cycles after the
time-limited repair installation or within 4,500 flight cycles after the Revision 2 date of this service
bulletin, whichever occurs first.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
NOTE: Accomplishment of the Stiffener Replacements at LBL 6.15 and RBL 6.15 given in this service
bulletin terminates the inspection requirements in accordance with Boeing Requirements
Bulletin 737-57A1339 RB.
Group 1, 3-8, Configuration 2:
Boeing recommends that the Installation of Bonding Fasteners and Bonding Jumpers, and Sealing of
Fasteners given in the service bulletin be done within 7,000 flight cycles or 27 months after the Revision
2 date of this service bulletin, whichever occurs first.
F. Approval
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.
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.
In addition, the Manager of the FAA Los Angeles ACO Branch approves the Stiffener Replacements;
Installation of Angle and Bonding Jumpers; and Installation of Bonding Fasteners and Bonding Jumpers,
and Sealing of Fasteners defined in this service bulletin as an alternative method of compliance to the
requirements of paragraphs (h) and (i) of AD 2005-20-01. All provisions of AD 2005-20-01 that are not
specifically referenced in the above statement remain fully applicable and must be complied with.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
In addition, the Manager of the FAA Los Angeles ACO Branch approves the Stiffener Replacements
defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs
(h) and (j) of AD 2018-10-12. All provisions of AD 2018-10-12 that are not specifically referenced in
the above statement remain fully applicable and must be complied with.
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These data have been reviewed by the Boeing ODA for fuel tank ignition prevention requirements, and
no further approval from the FAA Oversight Office is required to satisfy the requirements of CDCCL
28-AWL-11 provided the repair or alteration is accomplished in accordance with these instructions.
G. Manpower
The table below shows an estimate of the task-hours necessary to do this change 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 examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3:
STIFFENER REPLACEMENT AND INSTALLATION OF ANGLE AND BONDING JUMPERS
Elapsed HoursTask-HoursNumber of Per-
sons
Task
9.2537.004Open Access
20.5082.004Change
11.5046.004Close Access
1.002.002Test
42.25167.00TOTAL FOR EACH AIRPLANE
Group 4, Configuration 1, 3; Group 5, Configuration 1, 3; Group 6, Configuration 1, 3, 5-6;
Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6:
STIFFENER REPLACEMENT AND INSTALLATION OF ANGLE AND BONDING JUMPERS
Elapsed HoursTask-HoursNumber of Per-
sons
Task
5.2521.004Open Access
20.5082.004Change
6.5026.004Close Access
1.002.002Test
33.25131.00TOTAL FOR EACH AIRPLANE
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Group 1, 3-8, Configuration 2:
INSTALLATION OF BONDING FASTENERS AND BONDING JUMPERS, AND SEALING OF
FASTENERS
Elapsed HoursTask HoursNumber of PersonsTask
9.2537.004Open Access
4.504.501Change
11.5046.004Close Access
1.002.002Test
26.2589.50TOTAL FOR EACH AIRPLANE
Group 1, 3-8, Configuration 4:
None.
H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+1657.5+2.5All
I. Electrical Load Data
None.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 35005-239RS
b. Boeing Service Bulletin 737-57A1339
c. Boeing Service Related Problem (SRP) 737-SRP-57-0135, 737-SRP-57-0293,
737-SRP-57-0343
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-20-01, 2018-10-12
e. Standard Overhaul Practices Manual (SOPM) 20-11-03, 20-41-02, 20-43-03, 20-50-01
f. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-00, 20-20-10
g. 737-100/200 Aircraft Maintenance Manual (AMM) 07-11-11, 21-11-21, 21-51-21, 21-52-91,
24-22-00, 28-10-00, 28-12-11, 28-23-00, 29-12-21
h. 737-100/200 Structural Repair Manual (SRM) 51-10-01, 51-10-12
i. 737-300/400/500 Aircraft Maintenance Manual (AMM) 21-11-21, 21-51-21, 21-52-91, 24-22-00,
28-10-00, 29-15-22
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j. 737-300 Structural Repair Manual (SRM) 51-10-02, 51-80-01
k. 737-400 Structural Repair Manual (SRM) 51-10-02, 51-80-01
l. 737-500 Structural Repair Manual (SRM) 51-10-02, 51-80-01
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Pump Installation - A.C. Motor Driven, System B.65-44900
Pump Installation - A.C. Motor Driven, Hydraulic65C26850
These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs 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 but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability
information.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5, Configu-
ration 1, 3:
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the Revision 2
Date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 2 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
----Top Kit - Stiffener Re-
placement
65C38415-1 (a)(b)
14,730.003135August 24,
2018
Top Kit - Stiffener Re-
placement
65C38415-101
(b)(c)
22September 15,
2018
21October 22,
2018
8,700.0031312August 24,
2018
Supplemental Kit -
Stiffener Replacement
65C38415-201 (c)
12September 15,
2018
(a) Kit not available.
(b) The 65C38415-101 replaces the 65C38415-1.
(c) The 65C38415-1 plus the 65C38415-201 equals the 65C38415-101.
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Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3, 5-6:
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the Revision 2
Date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 2 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
----Top Kit - Stiffener Re-
placement
65C38415-2 (a)(b)
14,730.003132August 24,
2018
Top Kit - Stiffener Re-
placement
65C38415-102
(b)(c)
8,700.003132August 24,
2018
Supplemental Kit -
Stiffener Replacement
65C38415-202 (c)
(a) Kit not available.
(b) The 65C38415-102 replaces the 65C38415-2.
(c) The 65C38415-2 plus the 65C38415-202 equals the 65C38415-102.
Group 1, 3-8, Configuration 2:
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the Revision 2
Date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 2 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
3,410.002905August 24,
2018
Supplemental Kit -
Stiffener Replacement
65C38415-203
10September 15,
2018
9September 28,
2018
Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to
help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and repair procedures given in this
service bulletin.
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### Page 45

C. Parts Necessary for Each Airplane
1. Kits/Parts:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration
1, 3; Group 5, Configuration 1, 3:
65C38415-201 supplemental kit plus 65C38415-1 top kit is equivalent to 65C38415-101
replacement kit.
Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
65C38415-202 supplemental kit plus 65C38415-2 top kit is equivalent to 65C38415-102
replacement kit.
Group 1, 3-8, Configuration 2:
65C38415-203 is necessary for installation of grounding fasteners and bonding jumpers.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group
5, Configuration 1, 3:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-201-101
--TOP KIT - STIFF-
ENER REPLACE-
MENT, WING
CENTER SEC-
TION
.-65C38415-101
--SUPPLEMENTAL
KIT - STIFFENER
REPLACEMENT,
WING CENTER
SECTION
-.65C38415-201
--BOLT.26-72493-3
--EYEBOLT.16-72493-4
(a)(b)(c)(e)STIFFENER -
REAR SPAR,
WING CENTER
SECTION
.165C30036-1
(a)(b)(c)(f)STIFFENER -
REAR SPAR,
WING CENTER
SECTION
.165C30036-2
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### Page 46

Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group
5, Configuration 1, 3:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-201-101
--FILLER.265C38415-3
--FILLER.165C38415-4
--FILLER.165C38415-5
--SHIM - LAMINAT-
ED
.265C38415-6
--SHIM - LAMINAT-
ED
.265C38415-7
--SHIM - LAMINAT-
ED
.165C38415-8
--SHIM - LAMINAT-
ED
.165C38415-9
--BRACKET, WING
CTR SECTION,
JUMPER CABLE,
HYDRAULIC
PUMP
11691A6001-1
--SLEEVE44828U4812-113
(d)-BOLT88BACB30MB10A7
(d)-BOLT, PROTRUD-
ING HD
33BACB30MB6A4
(d)-BOLT, PROTRUD-
ING HD
2020BACB30MB6A7
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB6A8
(d)-BOLT, PROTRUD-
ING HD
22BACB30MB6A9
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB8A3
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB8A6
(d)-BOLT22BACB30MD10A11
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD10A12
(d)-BOLT O/S44BACB30MD10A13
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### Page 47

Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group
5, Configuration 1, 3:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-201-101
(d)-BOLT, PROTRUD-
ING HD
44BACB30MD10A14
(d)-BOLT, HEX DRIVE44BACB30MD10A17
(d)-BOLT66BACB30MD10A7
(d)-BOLT, HEX DRIVE22BACB30MD6A3
(d)-BOLT1818BACB30MD6A4
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD6A5
(d)-BOLT1010BACB30MD6A6
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD6A7
(d)-BOLT, PROTRUD-
ING HD
1010BACB30MD6A8
(d)-BOLT22BACB30MD8A11
(d)-BOLT11BACB30MD8A4
(d)-BOLT, PROTRUD-
ING HD
3232BACB30MD8A7
(d)-BOLT1010BACB30MD8A8
(d)-BOLT44BACB30MD8A9
--COLLAR.16BACC30AC10
--COLLAR1444BACC30AC6
--COLLAR.47BACC30AC8
--COLLAR88BACC30BH10
--COLLAR2929BACC30BH6
--COLLAR88BACC30BH8
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-36
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-54
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### Page 48

Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group
5, Configuration 1, 3:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-201-101
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-56
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-60
--NUT.3BACN10JC4
--NUT44BACN10YR5CD
--RIVET.2BACR15BB4D6C
--RIVET, UNIVER-
SAL HD
44BACR15BB4D7C
--SCREW44BACS12GU5K8
--GROMMET.1MS35489-12
--GROMMET.1MS35489-148
--WASHER16NAS1149D0463J
--WASHER1212NAS1149D0516H
(a) Discard the existing part.
(b) This part is not used in production.
(c) You cannot use the existing part to replace the new or changed part.
(d) If grip length shown is not available at Boeing, fasteners supplied in kits may
be one grip length longer than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded, substitute fasteners may be
supplied in kits.
(e) 65-45402-38; or 69-62014-1, or -2, or -3, or -4, or -6.
(f) 65-45402-47, or -279, or -356, or -384, or -590.
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### Page 49

Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1,
3, 5-6:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-202-102
--TOP KIT - STIFF-
ENER REPLACE-
MENT, WING
CENTER SEC-
TION
.-65C38415-102
--SUPPLEMENTAL
KIT - STIFFENER
REPLACEMENT,
WING CENTER
SECTION
-.65C38415-202
(a)(b)(c)(e)STIFFENER -
REAR SPAR,
WING CENTER
SECTION
.165C30036-1
(a)(b)(c)(f)STIFFENER -
REAR SPAR,
WING CENTER
SECTION
.165C30036-2
--FILLER.265C38415-3
--FILLER.165C38415-4
--FILLER.165C38415-5
--SHIM - LAMINAT-
ED
.265C38415-6
--SHIM - LAMINAT-
ED
.265C38415-7
--SHIM - LAMINAT-
ED
.165C38415-8
--SHIM - LAMINAT-
ED
.165C38415-9
--BRACKET, WING
CTR SECTION,
JUMPER CABLE,
HYDRAULIC
PUMP
11691A6001-1
--SLEEVE44828U4812-113
(d)-BOLT88BACB30MB10A7
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### Page 50

Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1,
3, 5-6:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-202-102
(d)-BOLT, PROTRUD-
ING HD
99BACB30MB6A4
(d)-BOLT, PROTRUD-
ING HD
2020BACB30MB6A7
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB6A8
(d)-BOLT, PROTRUD-
ING HD
22BACB30MB6A9
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB8A3
(d)-BOLT, PROTRUD-
ING HD
44BACB30MB8A6
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD10A12
(d)-BOLT O/S44BACB30MD10A13
(d)-BOLT, HEX DRIVE44BACB30MD10A17
(d)-BOLT66BACB30MD10A7
(d)-BOLT2323BACB30MD6A4
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD6A5
(d)-BOLT1010BACB30MD6A6
(d)-BOLT, PROTRUD-
ING HD
22BACB30MD6A7
(d)-BOLT, PROTRUD-
ING HD
1010BACB30MD6A8
(d)-BOLT11BACB30MD8A4
(d)-BOLT, PROTRUD-
ING HD
3232BACB30MD8A7
(d)-BOLT1010BACB30MD8A8
(d)-BOLT22BACB30MD8A9
(d)-BOLT, PROTRUD-
ING HD
77BACB30NX6K4X
(d)-BOLT, 100 DEG
HEX DR
22BACB30YP6K4
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### Page 51

Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1,
3, 5-6:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-202-102
--COLLAR.16BACC30AC10
--COLLAR1447BACC30AC6
--COLLAR.45BACC30AC8
--COLLAR88BACC30BH10
--COLLAR4242BACC30BH6
--COLLAR88BACC30BH8
--COLLAR22BACC30BL6
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-36
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-54
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-56
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
11BACJ40E30-60
--NUT44BACN10YR5CD
--SCREW44BACS12GU5K8
--GROMMET.1MS35489-12
--GROMMET.1MS35489-148
--WASHER1212NAS1149D0516H
(a) Discard the existing part.
(b) This part is not used in production.
(c) You cannot use the existing part to replace the new or changed part.
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### Page 52

Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1,
3, 5-6:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-202-102
(d) If grip length shown is not available at Boeing, fasteners supplied in kits may
be one grip length longer than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded, substitute fasteners may be
supplied in kits.
(e) 65-45402-38; or 69-62014-1, or -2, or -3, or -4, or -6.
(f) 65-45402-47, or -279, or -356, or -384, or -590.
Group 1, 3-8, Configuration 2:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-203
--SUPPLEMENTAL
KIT - STIFFENER
REPLACEMENT,
WING CENTER
SECTION
-65C38415-203
--BRACKET, WING
CTR SECTION,
JUMPER CABLE,
HYDRAULIC
PUMP
1691A6001-1
--SLEEVE4828U4812-113
(a)-BOLT8BACB30MB10A7
(a)-BOLT, PROTRUD-
ING HD
4BACB30MB8A3
(a)-BOLT, PROTRUD-
ING HD
4BACB30MB8A6
--COLLAR8BACC30BH10
--COLLAR8BACC30BH8
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
1BACJ40E30-36
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### Page 53

Group 1, 3-8, Configuration 2:
Kit 65C38415
NotesExisting Part
Number
NameQTYNew Part Number
-203
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
1BACJ40E30-54
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
1BACJ40E30-56
--JUMPER ASSEM-
BLY, MAIN POW-
ER SHIELDS, 200
AMPERE
1BACJ40E30-60
--NUT4BACN10YR5CD
--SCREW4BACS12GU5K8
--WASHER12NAS1149D0516H
(a) If grip length shown is not available at Boeing, fasteners supplied in kits
may be one grip length longer than indicated. Also, if any fasteners part
numbers listed are not available or have been superseded, substitute
fasteners may be supplied in kits.
2. Parts and Materials Supplied by the Operator:
Group 1, Configuration 2, 4; Group 2; Group 3, Configuration 2, 4; Group 4, Configuration
2, 4; Group 5, Configuration 2, 4; Group 6, Configuration 2, 4; Group 7, Configuration 2, 4;
Group 8, Configuration 2, 4:
None.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3; Group 7, Configuration 1, 3; Group 8, Configuration
1, 3:
NotesNameQTYPart Number /
Specification
Refer to BSOPM 20-43-03Chemical Conversion Treatment8 ozType 2, Class A
(a)Primer1 ptBMS 10-11, Type I
(a) 702 White GlossEnamel1 ptBMS 10-11, Type II
(a)Sealant1 ptBMS 5-45
(a)Sealant1 ptBMS 5-95, Type I
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Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3; Group 7, Configuration 1, 3; Group 8, Configuration
1, 3:
NotesNameQTYPart Number /
Specification
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
Group 6, Configuration 5-6; Group 7, Configuration 5-6; Group 8, Configuration 5-6:
NotesNameQTYPart Number /
Specification
Refer to BSOPM 20-43-03Chemical Conversion Treatment8 ozType 2, Class A
(a)Primer1 ptBMS 10-11, Type I
(a) 702 White GlossEnamel1 ptBMS 10-11, Type II
(a)Sealant1 ptBMS 5-45
(a)Sealant1 ptBMS 5-95, Type I
-Bolt3BACB30MD10A10
-Bolt2BACB30MD10A18
-Bolt1BACB30MD10A9
-Bolt1BACB30MD6A10
-Bolt3BACB30MD6A9
-Bolt2BACB30MD8A10
-Bolt5BACB30MD8A8
-Bolt1BACB30MD8A9
(a) See 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.
D. Parts Necessary to Change Spares
None.
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### Page 55

E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 57

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
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.
CAUTION
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).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 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. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,
and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.
6. The necessary conditions for selection of clamp type and size are included in SWPM
20-10-12. If any wire bundle support clamp specified in this service bulletin does not
make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted
procedure to select a clamp that fits correctly.
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7. 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. Refer to SOPM 20-50-01 for alternate
full threaded fasteners (screws) needed for installation in this service bulletin.
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. 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.
10. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
11. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
B. WORK INSTRUCTIONS
Group 2:
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 2 (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 1, 3-8, Configuration 4:
1. No further action required.
PART I - STIFFENER INSPECTION - ALL GROUPS
1. PART I is deleted at Revision 2 of this service bulletin.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3:
PART II: ACCESS AND REMOVALS FOR STIFFENER REPLACEMENT
1. Groups 1 and 3 - Refer to 737-100/200 AMM 28-12-11 and remove the fuel cell from the center
tank.
2. Groups 4 and 5 - Refer to 737-100/200 AMM 28-23-00 and de-fuel the center tank.
3. Refer to 737-100/200 AMM 07-11-11 and put the airplane on jacks.
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### Page 59

4. Refer to 737-100/200 AMM 29-12-21 and remove the two Hydraulic System B Motor Driven Pumps.
5. Refer to 737-100/200 AMM 24-22-00 and remove electrical power from the airplane. Disconnect
electrical wires from the ground studs installed on the stiffeners at LBL and RBL 6.15. Move and
hold the wires away from the repair area during the replacement of the stiffeners.
6. Remove hydraulic components from the repair area to get access to the stiffeners at LBL 6.15 and
RBL 6.15.
7. As necessary, remove components from the left and right air conditioning equipment bays to get
access to the forward surface of the wheel well bulkhead at LBL and RBL 6.15. Refer to 737-100/200
AMM 21-11-21, 21-51-21 and 21-52-91.
8. Refer to Figure 2 and remove the left pump support assembly.
9. Refer to Figure 3 and remove the right pump support assembly.
10. Refer to Figure 4 and remove the angle between LBL 6.15 and RBL 6.15.
11. Group 1, 3-5, Configuration 3:
Remove repair straps and channels related to the time-limited repair from stiffeners at LBL 6.15
and RBL 6.15. The removal of the time-limited repair can be done as part of the removal of the
stiffeners.
Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8, Configuration 1, 3,
5-6:
PART III: ACCESS AND REMOVALS FOR STIFFENER REPLACEMENT
1. Refer to 737-300/400/500 AMM 28-10-00 and remove the fuel and purge the center tank.
2. Refer to 737-100/200 AMM 07-11-11 and put the airplane on jacks.
3. Refer to 737-300/400/500 AMM 29-15-22 and remove the Hydraulic Systems A and B Motor Driven
Pumps.
4. Refer to 737-300/400/500 AMM 24-22-00 and remove electrical power from the airplane. Disconnect
electrical wires from the ground studs installed on the stiffeners at LBL and RBL 6.15. Move and
hold the wires away from the repair area during the replacement of the stiffeners.
5. Remove hydraulic components from the repair area to get access to the stiffeners at LBL 6.15 and
RBL 6.15
6. As necessary, remove components from the left and right air conditioning equipment bays to get
access to the forward surface of the wheel well bulkhead at LBL and RBL 6.15. Refer to
737-300/400/500 AMM 21-51-21, 21-52-61, and 21-52-91.
7. Refer to Figure 5 and remove the left pump support assembly.
8. Refer to Figure 6 and remove the right pump support assembly.
9. Refer to Figure 4 and remove the angle between LBL 6.15 and RBL 6.15.
Export Controlled ECCN: 9E991 - BOEING
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### Page 60

10. Group 6, Configuration 3, 5; Group 7, Configuration 3, 5; Group 8, Configuration 3, 5:
Remove repair straps and channels related to the time-limited repair from stiffeners at LBL 6.15
and RBL 6.15. The removal of the time-limited repair can be done as part of the removal of the
stiffeners.
Group 1, Configuration 1, 3; Group 3, Configuration 1, 3; Group 4, Configuration 1, 3; Group 5,
Configuration 1, 3; Group 6, Configuration 1, 3, 5-6; Group 7, Configuration 1, 3, 5-6; Group 8,
Configuration 1, 3, 5-6:
PART IV: LBL 6.15 STIFFENER REPLACEMENT
1. Group 1- Refer to Figure 7 and remove the stiffener.
2. Groups 3 and 5 - Refer to Figure 8 and remove the stiffener.
3. Group 4 - Refer to Figure 9 and remove the stiffener.
4. Groups 6, 7, and 8, Configuration 1,3 - Refer to Figure 10 and remove the stiffener.
Groups 6, 7, and 8, Configuration 5-6 - Refer to Figure 60 and remove the stiffener.
5. All Groups - Refer to Figure 11 and remove the gusset and grommet.
6. Groups 1, 3, 4, and 5 - Refer to Figure 12 and install the nut-plates and make the marks on the
new stiffener.
7. Group 6 - Refer to Figure 13 and drill the holes, install the ground studs, and make the marks on
the new stiffener.
8. Group 7 - Refer to Figure 14 and drill the holes, install the ground studs, and make the marks on
the new stiffener.
9. Group 8 - Refer to Figure 15 and drill the holes, install the ground studs, and make the marks on
the new stiffener.
10. Group 1- Refer to Figure 16 and do the stiffener pre-installation procedures.
11. Groups 3 and 5 - Refer to Figure 17 and do the stiffener pre-installation procedures.
12. Group 4 - Refer to Figure 18 and do the stiffener pre-installation procedures.
13. Groups 6, 7, and 8, Configuration 1,3 - Refer to Figure 19 and do the stiffener pre-installation
procedures.
Groups 6, 7, and 8, Configuration 5-6 - Refer to Figure 61 and do the stiffener pre-installation
procedures.
14. Group 1 - Refer to Figure 20 and install the stiffener.
15. Groups 3 and 5 - Refer to Figure 22 and install the stiffener.
16. Group 4 - Refer to Figure 23 and install the stiffener.
17. Groups 6, 7 and 8, Configuration 1,3 - Refer to Figure 24 and install the stiffener.
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