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Commercial Airplanes 737 Service Bulletin Number: 737-57A1271 Original Issue: September 11, 2003 Revision 3: February 13, 2012 ATA System: 5752 SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 3 B. Concurrent Requirements ...................................... 2 3 C. Reason ................................................ 2 3 D. Description .............................................. 2 5 E. Compliance .............................................. 2 6 F. Approval ............................................... 2 7 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary For Each Airplane ................................. 3 1
1. Kits/Parts: ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 3
4. Parts Removed and Not Replaced: .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: INSPECTION - TRACK WEBS AND FLANGES ....................... 4 2 FIGURE 2: INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED .......... 4 4 FIGURE 3: INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED ........ 4 6 FIGURE 4: REPLACEMENT - ANTI-FRET STRIP ............................ 4 8 FIGURE 5: REPLACEMENT - TAPERED SHIM .............................. 5 0 FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT ..................... 5 2 FIGURE 7: ALIGNMENT - TRACK INSTALLATION ............................ 5 7 FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200 .... 6 3 FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500 . . 68 FIGURE 10: SHOP AID - PRESSURE PLATE ............................... 7 2 FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15 ...... 7 3
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Commercial Airplanes 737 Service Bulletin Revision Transmittal SheetNumber: 737-57A1271Original Issue: September 11, 2003 Revision 3: February 13, 2012 ATA System: 5752 SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with Revision 2 of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 78-13-07, AD 90-06-02, AD 2000-25-07 & AD 2002-05-07 are related to this service bulletin.
REASON FOR REVISION This revision is sent to incorporate Information Notice 737-57A1271 IN 02. This Information Notice informed operators that sheet 2 of 3 in Figure 1 should be ignored. References to the related AD's were added and additional notes were added to section 3.A. General Information.
These sections were changed:
1. Figure 1 was revised to remove the graphic on sheet 2 of 3.
2. 3.A. General Information, additional notes were added.
3. 1.F. Approval, updated to the current statement.
The data given in Information Notice 737-57A1271 IN 02 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY September 11, 2003Original Issue:
July 30, 2008Revision 1:
January 17, 2011Revision 2:
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Original Issue: September 11, 2003 737-57A1271Revision 3: February 13, 2012 5 of 77
February 13, 2012Revision 3:
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Original Issue: September 11, 2003 737-57A1271Revision 3: February 13, 2012 6 of 77 BOEING SERVICE BULLETIN 737-57A1271
Commercial Airplanes 737 Service Bulletin SummaryNumber: 737-57A1271Original Issue: September 11, 2003 Revision 3: February 13, 2012 ATA System: 5752 SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives the instructions to inspect, repair, overhaul, and replace the flap track at Wing Buttock Line (WBL) 254.
Since 1989, Boeing has more than thirty reports of cracks in the flap track at WBL 254. Cracks were found in the area of the rear spar attachment, in the track webs, and in the upper and lower flanges at the aft end of the track. The cracks in the area of the rear spar attachment were found at the edge of the hole for the outboard bolt, or at the outer edge of the flange adjacent to the outboard bolt. The cracks in the upper and lower flanges were 0.1 to 1.5 inches in length, and the cracks in the aft end of the webs were 0.75 to 7.0 inches in length. In one incident the aft end of a track had cracks through the two lower flanges, through the two webs, and through the fail-safe spacer. The two upper flanges were all that kept the aft end attached to the remaining part of the track. Also, a track was found with cracks through the two upper and two lower flanges, and through the two webs. The fail-safe spacer was all that kept the aft end of this track attached. This track also had a piece broken out in the curved area of the upper outboard flange.
Some of the reports also show that tracks were found loose and had corrosion in the area of the rear spar attachment. These tracks that were found loose also had damaged, or missing, anti-fret strips and tapered shims. Initially, the loose tracks were thought to be caused by a weak bond of, or compression damage to, the phenolic anti-fret strip installed in the joint between the track and rear spar. But, subsequent reports showed that the sequence and procedures used during track installation could also be a cause of loose tracks. During installation, when full torque is applied to the forward attach bolt, it can cause the track to move laterally at the rear spar joint. If the track moves laterally at the rear spar joint during the installation procedures, it can put a side load on the inboard aft attach bolt. Then, when the inboard aft attach bolt is tightened to the specified torque value, some of the torque can be absorbed by friction. Subsequently, because of the friction, the torque applied to the bolt is not sufficient to hold the track tight against the rear spar structure.
Continued operation with a cracked and/or loose attachment at the rear spar could cause the track to break. A result of a broken track could be the loss of the outboard trailing edge flap, and may preclude continued safe flight and landing of the airplane.
The new spares track assemblies have increased upper flange thickness in the attachment area that mates with the wing rear spar, and improved coatings and processes for corrosion protection. The new track for the 737-100/200 also has an improved fail-safe configuration at the forward end that makes it comparable to the 737-300/400/500 track assembly.
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The inspections given in this service bulletin will find the conditions that make repair or replacement of the flap track necessary. The repairs, scheduled overhauls, correct alignment during installation, and regularly scheduled maintenance will keep tracks in a serviceable condition. There is no terminating action for this service bulletin.
This service bulletin replaces Service Bulletins 737-57A1082, 737-57A1249, and 737-57A1265.
Boeing Service Related Problem (SRP) 737-SRP-57-0131 is related to this service bulletin.
ACTION (PRR 35005-238RS) Do an initial inspection of the track webs, track flanges, and the track-to-wing attachment at WBL 254. Look for stop-drill repairs and cracks in the track webs. Look for stop-drill repairs, cracks, nicks, corrosion pits, galling, and other signs of damage on the track flanges. Look for corrosion, loose bolts, and a damaged or a missing anti-fret strip and/or tapered shim at the track-to-wing attachment.
Remove a track from service if it has a stop-drill repair. If possible, make repairs to the edges of the track flange, but replace the track if cracks are found in the webs.
Disassemble the track-to-wing joint and do more inspections if signs of corrosion, loose bolts, or a damaged or missing anti-fret strip or tapered shim are found. If necessary make and install a new anti-fret strip, and/or tapered shim, and remove corrosion and make repairs to the track. Do the procedures to correctly align the track during assembly of the track-to-wing joint. If the track cannot be repaired, install a serviceable flap track assembly.
During installation of a serviceable flap assembly, do the procedures to correctly align the track during installation.
Do the repeat inspections and schedule the initial, and repeat overhaul, of a flap track at the times given in Paragraph 1.E., Compliance.
Flap track assemblies with short fail-safe bars, part number 65-46428-31 and 65-46428-33 must be removed from service during inspection or repair.
EFFECTIVITY All 737-100, -200, -200C, -300, -400, and -500 airplanes line numbers 1 through 3132.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 78-13-07, AD 90-06-02, AD 2000-25-07 & AD 2002-05-07 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance, for the repeat inspection and overhaul thresholds.
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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures, given in this service bulletin.
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Original Issue: September 11, 2003 737-57A1271Revision 3: February 13, 2012 8 of 77 BOEING SERVICE BULLETIN 737-57A1271
BOEING SERVICE BULLETIN 737-57A1271
MANPOWER Airplanes Total Task Hours Elapsed Hours All 82 23
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
WBL INSPECT TRACK WEB 254 AND FLANGES SEE
LEFT WING SHOWN FWDY
RIGHT WING SIMILAR A-A (EXAMPLE - CRACKS AND DAMAGE) ATTACH BOLTS
AFT TRACK SUPPORT
FITTING
LOWER WING SKIN
REAR SPAR
INSPECT TRACK CHORD
ATTACHMENT OVERHAUL TRACKS AT NEW INTERVALS.
FOR INCREASED CORROSION PROTECTION
FWD, AND SERVICE LIFE, REPLACE TRACKS WITH NEW SPARES TRACKS.
> INBD FLAP TRACKS 2 AND 7 N85000 Original Issue: September 11, 2003 Revision 3: February 13, 2012 737-57A1271 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 9 of 77
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Commercial Airplanes 737 Service Bulletin Number: 737-57A1271 Original Issue: September 11, 2003 Revision 3: February 13, 2012 ATA System: 5752 SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254
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.
DESCRIPTIONCONFIGURATIONGROUP 737-100/-200/-200C, airplanes with flap track assemblies 65-46428-() or 65C35380-(). Inspection, overhaul and replacement instructions given are applicable to Group 1 airplanes -1 737-200/-200C, airplanes with flap track assemblies 65-67158-() or 65C35380-(). If necessary, these tracks can be replaced with 65-67158-6.
-2 737-300/400/500 airplanes with 65-46428-(), 65C35616-(), 65C35387-(), 65C34812-() or 65C35380-() flap track assemblies.
The inspection, overhaul, and replacement instructions given in this service bulletin are applicable to Group 3 airplanes.
-3 Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 2PC001 - PC005 1PG001 - PG075
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GroupVariable Number 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 - PH013 1PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH743 2PJ001 - PJ002 1PJ003 - PJ009 2PJ031 - PJ032 2PJ071 - PJ072 2PJ101 - PJ104 1PJ105 - PJ119 1PJ201 - PJ219 3PJ301 - PJ302 3PJ551 - PJ561 3PJ601 - PJ615 3PJ811
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