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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-57A1321 Original Issue: February 08, 2019 ATA System: 5710 2811 SUBJECT: WINGS - Main Frame - Fuel Tank Fastener Sealant Application, Wire Bundle Clamp Replacement and Teflon Sleeve Installation 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 © 2019 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Unpublished Work.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: February 08, 2019 737-57A1321 1 of 289
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 08, 2019 737-57A1321 2 of 289 BOEING SERVICE BULLETIN 737-57A1321
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Table of Contents
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 3 8 B. Concurrent Requirements ...................................... 3 8 C. Reason ................................................ 3 8 D. Description .............................................. 3 8 E. Compliance .............................................. 3 9 F . A p p r o v a l ............................................... 4 0 G. Manpower .............................................. 4 0 H. Weight and Balance Changes .................................... 4 3 I. Electrical Load Data ......................................... 4 3 J . R e f e r e n c e s .............................................. 4 4
1. Existing Data: ......................................... 4 4
2. Data Supplied with this Service Bulletin: ........................... 4 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 4 K. Publications Affected ........................................ 4 5 L. Interchangeability and Intermixability of Parts ........................... 4 5 M. Software Accomplishment Summary ................................ 4 5
2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 7 C. Parts Necessary for Each Airplane ................................. 4 7 1 . K i t s / P a r t s ............................................ 4 7
2. Parts and Materials Supplied by the Operator ........................ 4 7
3. Parts Modified and Reidentified ................................ 4 8
4. Parts Removed and Not Replaced .............................. 4 8 D. Parts Necessary to Change Spares ................................. 4 8 E. Special Tooling - Price and Availability ............................... 4 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 1 FIGURE 1: LEFT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [ Group 2-48, 56-59] . 58 FIGURE 2: LEFT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [ G r o u p 3 7 - 4 8 ] .... 6 1 FIGURE 3: LEFT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [ G r o u p 4 9 - 5 5 ] .... 6 3 FIGURE 4: RIGHT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [Group 2-48, 56-59] . 65 FIGURE 5: RIGHT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [Group 37-48] . . . 68 FIGURE 6: RIGHT WING REAR SPAR - FUEL TANK FASTENERS - LOCATION [Group 49-55] . . . 70 FIGURE 7: LEFT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATION [Group 2-7, 37-48, 56-59] .................................................. 7 2 FIGURE 8: LEFT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATION [ G r o u p 8 - 3 6 ] .... 7 4 FIGURE 9: LEFT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATION [Group 2-48, 56-59] . 76 FIGURE 10: LEFT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATION [Group 49-55] . . . 93 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 11: RIGHT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATIO N [Group 2-7, 37-48, 5 6 - 5 9 ] ............................................. 1 1 2 FIGURE 12: RIGHT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATIO N [Group 8-36] . . 114 FIGURE 13: RIGHT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATIO N [Group 2-48, 56-59] ................................................. 1 1 6 FIGURE 14: RIGHT WING FRONT SPAR - FUEL TANK FASTENERS - LOCATIO N [Group 49-55] . 132 FIGURE 15: WING CENTER SECTION REAR SPAR - FUEL TANK FASTENERS - LOCATION [Group 2-48, 5 6 - 5 9 ] ............................................. 1 5 0 FIGURE 16: WING CENTER SECTION REAR SPAR - FUEL TANK FASTENERS - LOCATION [Group 49-55] ................................................. 1 5 3 FIGURE 17: WING CENTER SECTION FRONT SPAR - FUEL TANK FASTENERS - LOCATION [Group 2 - 7 , 5 6 - 5 9 ] ........................................... 1 5 8 FIGURE 18: WING CENTER SECTION FRONT SPAR - FUEL TANK FASTENERS - LOCATION [Group 8 - 5 5 ] .............................................. 1 6 5 FIGURE 19: LEFT WING RIB INSTALLATION - FUEL TANK FASTENERS - LO CATION [Group 2, 4-55] ................................................. 1 7 2 FIGURE 20: LEFT WING RIB INSTALLATION - FUEL TANK FASTENERS - LO CATION [Group 3, 56-59] ................................................. 1 7 9 FIGURE 21: RIGHT WING RIB INSTALLATION - FUEL TANK FASTENERS - L OCATION [Group 2, 4-55] ................................................. 1 8 5 FIGURE 22: RIGHT WING RIB INSTALLATION - FUEL TANK FASTENERS - L OCATION [Group 3, 56-59] ................................................. 1 9 2 FIGURE 23: FUEL TANK FASTENERS - SEALANT APPLICATION [Group 2-59 ] ........... 1 9 8 FIGURE 24: LEFT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 2-4, 6, 8, 10, 12, 16-17, 20, 24-25, 30-31, 37, 40, 42, 45, 47, 49, 51-52, 5 6 , 5 8 ] ............................................. 2 0 0 FIGURE 25: LEFT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 9, 11, 18, 26, 28, 32-33, 35-36, 38, 41, 46 , 5 0 ] .......... 2 0 4 FIGURE 26: LEFT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 5, 7, 13, 15, 19, 21-23, 27, 39, 43, 53, 55 , 5 7 , 5 9 ] ........ 2 0 8 FIGURE 27: LEFT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 14, 29, 34, 44, 48, 54] ....................... 2 1 2 FIGURE 28: RIGHT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEME NT AND TEFLON SLEEVE INSTALLATION [Group 2-8, 10, 12-13, 15-17, 19-25, 27, 30-31, 37, 39-40, 42-43, 45, 4 7 , 4 9 , 5 1 - 5 3 , 5 5 - 5 9 ] ..................................... 2 1 6 FIGURE 29: RIGHT WING REAR SPAR - WIRE BUNDLES - CLAMP REPLACEME NT AND TEFLON SLEEVE INSTALLATION [Group 9, 11, 14, 18, 26, 28-29, 32-36, 38, 41, 44, 46, 48, 50, 54] ................................................. 2 2 0 FIGURE 30: LEFT WING FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEME NT AND TEFLON SLEEVE INSTALLATION [Group 2-7, 16, 20-21, 23-24, 30, 56-59] . . .......... 2 2 4 FIGURE 31: LEFT WING FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEME NT AND TEFLON SLEEVE INSTALLATION [Group 8-15, 17-19, 22, 25-29, 31-55] ............. 2 2 9 FIGURE 32: RIGHT WING FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEM ENT AND TEFLON SLEEVE INSTALLATION [Group 2-59] ........................... 2 3 4 FIGURE 33: FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 2, 8-9] ......... 2 3 9 FIGURE 34: FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 3, 10-15] . . ..... 2 4 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 35: FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 4-7, 16-32, 37-45, 49-59] ................................................. 2 4 5 FIGURE 36: FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 33-35] ......... 2 4 8 FIGURE 37: FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 36, 46-48] . . .... 2 5 1 FIGURE 38: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 10-11, 16-19, 36-39, 46, 4 9 - 5 0 ] ..... 2 5 4 FIGURE 39: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 2, 4, 8-9, 12, 20, 40-41, 47, 51, 56] . . . 259 FIGURE 40: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 13-14, 21-22, 42-44, 48, 5 2 - 5 4 ] ..... 2 6 4 FIGURE 41: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 5, 15, 23, 55, 57] ............ 2 6 9 FIGURE 42: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 24-27, 33] ................ 2 7 4 FIGURE 43: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 28-29, 34] ................ 2 7 9 FIGURE 44: MAIN WHEEL WELL STATION 663 BULKHEAD - WIRE BUNDLES - CLAMP REPLACEMENT AND TEFLON SLEEVE INSTALLATION [Group 3, 6-7, 30-32, 35, 45, 58 - 5 9 ] ...... 2 8 4 APPENDIX A: TEFLON SLEEVE INSTALLATION AT LOCATIONS WITH WIRE BUNDLE/WIRE BREAKOUT THAT HAVE SMALL BEND RADIUS [Group 2-59] ..................... 2 8 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-57A1321Original Issue: February 08, 2019 ATA System: 5710 2811 SUBJECT: WINGS - Main Frame - Fuel Tank Fastener Sealant Application, Wire Bundle Clamp Replacement and Teflon Sleeve Installation
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will reduce the risk of ignition sources in the fuel tanks. If this service bulletin is not done, there is a higher risk of ignition sources in the fuel tanks which can cause a fire or an explosion.
Boeing has found that some fuel tank fasteners can be an ignition source if a fault current or hot short occurs.
A detailed analysis of the fault current threats was done to find the configuration necessary to safely conduct the fault current threats without causing sparks in the fuel tanks. Application of sealant on the fasteners in the fuel tanks at the wing rear spars, front spars and upper wing rib shear ties decreases the risk of ignition sources at those fuel tank fastener locations. In addition, external to the fuel tanks at locations along the wing rear spars, front spars, the forward cargo compartment station 540 bulkhead and the main wheel well station 663 bulkhead, installation of cushion clamps over Teflon sleeves on wire bundles decreases metal-to-metal contact between the clamps and their support brackets and will help prevent hot shorts.
This service bulletin gives instructions to seal fuel tank fasteners in the fuel tanks at the wing rear spars, front spars and upper wing rib shear ties. This service bulletin also gives instructions to install cushion clamps over Teflon sleeves on wire bundles external to the fuel tanks at locations along the wing rear spars, front spars, the forward cargo compartment station 540 bulkhead and the main wheel well station 663 bulkhead.
This service bulletin is the result of the safety assessments conducted by Boeing under Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
For Continued Airworthiness, the Structural Repair Manual (SRM) has been revised to add a new Section 51-80-01, GENERAL - LIGHTNING, ELECTRICAL WIRING AND EQUIPMENT FAULT CURRENT REQUIREMENTS.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 08, 2019 737-57A1321 7 of 289
Airworthiness Limitations (AWL's) 28-AWL-31 and 28-AWL-32, listed in the 737-300/400/500 section of 737-100/200/300/400/500 AWL's and Certification Maintenance Requirements (CMR's) document, D6-38278-CMR, are related to this service bulletin.
Boeing Service Related Problems (SRP) 737-SRP-57-0236 and 737-SRP-57-0296 are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 57-10001 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access to the left main, right main and center fuel tanks. Seal fasteners on the rear spar, front spar and upper wing rib shear ties in the left main and right main fuel tanks. Seal fasteners on the rear spar and front spar in the center fuel tank.
External to the fuel tanks, get access to the wire bundle installation along the left and right wing rear spars and front spars, the forward cargo compartment station 540 bulkhead and the main wheel well station 663 bulkhead.
Replace wire bundle clamps and install Teflon sleeve under the clamps.
EFFECTIVITY All 737-300, 737-400, 737-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 737-57A1321
ALERT ALERT Group 2-59:
Boeing recommends that the modification given in this service bulletin be done within 5 years after the original issue date of this service bulletin.
Group 1:
Contact The Boeing Company for modification instructions and do the modification within 5 years after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.
GET ACCESS TO THE LEFT MAIN, RIGHT MAIN AND CENTER FUEL TANKS. SEAL FASTENERS ON
THE REAR SPAR, FRONT SPAR AND UPPER WING RIB SHEAR TIES IN THE LEFT MAIN AND RIGHT MAIN FUEL TANKS. SEAL FASTENERS ON THE REAR SPAR AND FRONT SPAR IN THE CENTER FUEL TANK.
EXTERNAL TO THE FUEL TANKS, GET ACCESS TO THE WIRE BUNDLE INSTALLATION ALONG THE
LEFT AND RIGHT WING REAR SPARS AND FRONT SPARS, THE FORWARD CARGO COMPARTMENT STATION 540 BULKHEAD AND THE MAIN WHEEL WELL STATION 663 BULKHEAD.
REPLACE WIRE BUNDLE CLAMPS AND INSTALL TEFLON SLEEVE UNDER THE CLAMPS.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-57A1321 Original Issue: February 08, 2019 ATA System: 5710 2811 SUBJECT: WINGS - Main Frame - Fuel Tank Fastener Sealant Application, Wire Bundle Clamp Replacement and Teflon Sleeve Installation
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 Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to all 737-300/400/500 Airplanes, in 59 Groups. The Variable Numbers and Group Information for the applicable airplanes are given below. Refer to PRR 35005-304RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 737-300/-400/-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-1 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-2 737-300 Airplane with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-3 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-4 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-6 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-7 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-8 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-9 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-10 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-11 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-12 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-13 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-14 737-500 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-15 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-16 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-17 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-18 737-300 Airplane with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-19 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-20 737-300 Airplanes with a different configuration of fuel tank fasteners and wire bundles than the other airplane groups.
-21 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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