Boeing ASB 737-57A1304: Revision 1, text

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Commercial Airplanes 737 Service Bulletin Number: 737-57A1304 Original Issue: June 02, 2008 Revision 1: August 11, 2009 ATA System: 5752 SUBJECT: Wings - Trailing Edge Flaps - Outboard Flap, Carriage Spindle- Inspection for Corrosion 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: June 02, 2008 737-57A1304Revision 1: August 11, 2009 1 of 37

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Original Issue: June 02, 2008 737-57A1304Revision 1: August 11, 2009 2 of 37 BOEING SERVICE BULLETIN 737-57A1304

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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 ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 3 J. References .............................................. 2 3

1. Existing Data .......................................... 2 3

2. Data supplied with this Service Bulletin ............................ 2 3

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 3 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4

2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5

1. Kits/Parts ............................................ 2 5

2. Parts and Materials Supplied by the Operator ........................ 2 5

3. Parts Modified and Reidentified ................................ 2 5

4. Parts Removed and Not Replaced .............................. 2 5 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: LOCATE PART NUMBER FOR CARRIAGES AT WBL 254 AND WBL 355 WITH HVOF THERMAL COATED SPINDLES ............................... 3 1 FIGURE 2: INSPECT CARRIAGES SPINDLES WITH HVOF THERMAL COATING FOR CORROSION [Group 1, Configuration 2] ................................... 3 3 APPENDIX A: SERIAL NUMBERS OF SUSPECT CARRIAGE SUB-ASSEMBLIES 65C27409-29 AND -31.

.................................................. 3 5

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Original Issue: June 02, 2008 737-57A1304Revision 1: August 11, 2009 4 of 37 BOEING SERVICE BULLETIN 737-57A1304

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Commercial Airplanes 737 Service Bulletin Revision Transmittal SheetNumber: 737-57A1304Original Issue: June 02, 2008 Revision 1: August 11, 2009 ATA System: 5752 SUBJECT: Wings - Trailing Edge Flaps - Outboard Flap, Carriage Spindle- Inspection for Corrosion This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive 2008-15-05, is related to this service bulletin.

No more work is necessary on airplanes changed as shown in the original issue of this service bulletin.

REASON FOR REVISION This revision is sent to add the warranty statement and update Appendix A by deleting table 1 and revising table

These sections were changed:

– In the Background and Reason section the service history was updated to include 13 additional reports.

– Throughout the Service bulletin, the terminating action has been expanded to include refurbished carriages that have a serial number with a R suffix or carriages that do not have a HVOF coating.

– The FAA Airworthiness Directive 2008-15-05 has been added to the Compliance sections and the AMOC statement was added to the Approval section.

– The Industry Support Information on the Summary page and Paragraph 2.B., Industry Support Information;

the warranty statement has been added.

– Paragraph 1.A.1. Airplanes, in the description for configuration 2; the word "suspect" was added prior to carriages.

– Paragraph 1.K. Publication Affected was updated to add the damage tolerance statement.

– In APPENDIX A Table 1 serial numbers were deleted and Table 2 was revised to reduce the serial number ranges showing each suspect serial number. A note was added saying serial numbers with a R suffix are not suspect.

– In APPENDIX A, Table 3 has been added to include additional serial numbers that were removed by AMOC letter 120S-08-854.

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 June 02, 2008Original Issue:

Original Issue: June 02, 2008 737-57A1304Revision 1: August 11, 2009 5 of 37

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August 11, 2009Revision 1:

Original Issue: June 02, 2008 737-57A1304Revision 1: August 11, 2009 6 of 37 BOEING SERVICE BULLETIN 737-57A1304

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Commercial Airplanes 737 Service Bulletin SummaryNumber: 737-57A1304Original Issue: June 02, 2008 Revision 1: August 11, 2009 ATA System: 5752 SUBJECT: Wings - Trailing Edge Flaps - Outboard Flap, Carriage Spindle- Inspection for Corrosion

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin provides instruction to inspect 737-300/400/500 carriage spindles with High Velocity Oxy-Fuel (HVOF) thermal coating that are installed at WBL 254 and WBL 355 on the outboard trailing edge flaps for corrosion. These carriages would have been installed during an overhaul or replacement that would have been conducted after February 2006. If the corrosion goes undetected it could lead to a fracture of the carriage spindle.

One fractured carriage spindle can be compensated for by the pilot with inputs to the aileron and or rudder.

However fractures of both the inboard and the outboard carriage spindles at the forward end of the spindle through the large diameter (the critical section), on a given outboard flap may preclude continued safe flight and landing of the airplane.

Boeing has received initial reports from two operators who have found corrosion on the carriage spindles that are located on the outboard trailing edge flaps. The affected carriages had been overhauled after February 2006 and the carriage sub-assembly had been replaced with a new carriage sub-assembly that had the HVOF thermal coating applied to the spindle. The HVOF thermal coating had flaked off exposing the base metal and allowing corrosion on the spindle. One of the two operators reported finding 8 carriages on 5 airplanes coated with the HVOF thermal coating, which had corrosion on the spindle. The other operator has found 1 carriage with corrosion. Since the initial release of this service bulletin, Boeing has received an additional 13 reports from operators of carriage spindles with corrosion. So far none of the HVOF thermal coated carriages have been reported with fractures.

Boeing has examined the parts returned from the operator for evidence of environmental contaminants as well as reviewing the manufacturing process to determine the cause. From review of our records, approximately 500 carriage sub-assemblies with the HVOF thermal coating have been delivered to the fleet for use during overhaul.

These carriages were all delivered after February 2006. Boeing has purged all suspect carriages from inventory, and all available spares have properly applied coating.

FAA AMOC letter 120S-08-854 removed the Table 1 serial numbers from the inspection requirements. A subsequent discovery of a similar problem with certain serial numbers included in the AMOC necessitates the addition of Table 3 to APPENDIX A.

Boeing Service Related Problem (SRP) 737-SRP-57-0221 is related to this service bulletin.

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ACTION Review your records or inspect for the carriage part number and/or serial number to determine if you have any of the suspect carriage sub-assemblies that have the HVOF thermal coating on the spindle. These carriages would only be on 737-300/400/500 classic airplanes that have inboard (WBL 254) or outboard (WBL 355) flap carriage assemblies that were overhauled or replaced after February 2006. If you determine that you do have suspect carriages with the HVOF thermal coating on the spindle, inspect for corrosion. Do a detailed inspection or a borescope inspection on the forward end of the spindle, that is forward of the flap front spar. Do a detailed inspection on the aft section of the spindle that is exposed when the access panel is removed. Inspect the HVOF thermal coated spindles in accordance with Paragraph 1.E., Compliance. Remove and replace carriages that are corroded with a new or serviceable carriage. Perform a gap check or a NDT ultrasonic inspection if no corrosion is found. If during your inspection you find potential indications of corrosion like flaking metallic particles, disbonded sealant, cracked paint or primer and you are not able to determine if corrosion is present, remove the carriage from the midflap and perform a detailed inspection for corrosion of the entire spindle surface. The replacement of a carriage that has the suspect HVOF thermal coating on the spindle with one that does not have this HVOF coating or one that has been refurbished and the serial number has a R suffix, will terminate the inspection in this service bulletin for that carriage only. If you determine that your airplane does not have any carriage with the HVOF thermal coating, then there is no further action required.

EFFECTIVITY 737-300, -400, -500 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Refer to Paragraph 1.E., Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive 2008-15-05 is related to this service bulletin.

The Federal Aviation Administration (FAA) will possibly release another 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 available for airplanes in warranty as of April 25, 2008. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION None.

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BOEING SERVICE BULLETIN 737-57A1304

REMOVE ACCESS PANEL SPINDLE

BEARING BEARING

SUPPORT

TRAILING

EDGE FLAP

CARRIAGE SERIAL

NUMBER LOCATION

DO A GAP CHECK OF THE

CARRIAGE SPINDLE

OUTBOARD

MIDFLAP

CARRIAGE

DO A DETAILED INSPECTION FOR CORROSION 360 DEGREES AROUND

THE CARRIAGE SPINDLES WITH HOF THERMAL COATING.

CARRIAGE PART AS AN OPTION USE A BORESCOPE TO NUMBER AND SERIAL INSPECT 360 DEGREES AROUND THE

NUMBER LOCATION SERIAL NUMBER ON PART NUMBER AND FORWARD SECTION OF THE SPINDLE

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes

DESCRIPTIONCONFIGURATIONGROUP 737-300, -400, -500 airplanes.-1 737-300, -400, -500 airplanes.1 737-300, -400, -500 airplanes with suspect carriages that have HVOF thermal coating on the spindle.

2 Airplane Models:

737-300, 737-400, 737-500 GroupVariable Number 1PJ301 - PJ302 1PJ551 - PJ561 1PJ601 - PJ615 1PJ811 1PJ816 - PJ817 1PM381 - PM399 1PM401 - PM417 1PM541 - PM564 1PP001 - PP054 1PP101 - PP169

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GroupVariable Number 1PP181 - PP199 1PP201 - PP205 1PP221 1PP231 - PP243 1PP281 - PP286 1PP301 - PP305 1PP351 - PP353 1PP376 - PP384 1PP391 - PP393 1PP401 - PP440 1PP471 - PP475 1PP501 - PP522 1PP631 - PP634 1PP651 - PP652 1PP671 - PP699 1PP701 - PP733 1PP771 - PP779 1PP801 - PP808 1PP821 - PP827 1PP831 - PP848 1PP851 - PP852 1PP861 - PP877 1PP891 - PP899 1PP901 - PP936 1PP946 - PP948 1PP951 - PP952 1PP961 - PP967 1PP981 - PP991 1PP993 1PQ001 - PQ016 1PQ026 - PQ041 1PQ051 - PQ092 1PQ101 - PQ199

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