Boeing ASB 737-71A1462: U.S. DOT/FAA - Service Bulletin, text

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ALERT ALERT Commercial Airplane Group 737

ALERTALERT Service Bulletin Number: 737-71A1462 Date: August 29, 2002 Revision 3 May 20, 2004 ATA System: 7121 SUBJECT: POWER PLANT - Engine Mounts - Aft Engine Mount, Link Assembly, Hanger Fitting, Inspection, Correction and Identification of Parts

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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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ALERT ALERT

BLANK PAGE

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ALERT ALERT Table of Contents

R e v i s i o n T r a n s m i t t a l S h e e t5

S u m m a r y7

1 . P L A N N I N G I N F O R M A T I O N ..................................... 1 1 A . E f f e c t i v i t y ............................................ 1 1 1 . A i r p l a n e s ......................................... 1 1 2 . S p a r e s A f f e c t e d ...................................... 2 4 B . C o n c u r r e n t R e q u i r e m e n t s................................... 2 5 C . R e a s o n ............................................ 2 5 D . D e s c r i p t i o n ........................................... 2 8 E . C o m p l i a n c e ........................................... 2 8 F . A p p r o v a l............................................ 2 9 G . M a n p o w e r ........................................... 3 0 H . W e i g h t a n d B a l a n c e C h a n g e s................................. 3 1 I . E l e c t r i c a l L o a d D a t a...................................... 3 1 J . R e f e r e n c e s ........................................... 3 1 1 . E x i s t i n g D a t a : ....................................... 3 1

2. Data supplied with this Service Bulletin:31

3. Installation Drawings Used in the Preparation of this Service Bulletin:31

4 . P r o c e s s D a t a : ....................................... 3 1 K . P u b l i c a t i o n s A f f e c t e d ...................................... 3 2 L . I n t e r c h a n g e a b i l i t y a n d I n t e r m i x a b i l i t y o f P a r t s......................... 3 2 2 . M A T E R I A L I N F O R M A T I O N ..................................... 3 3 A . M a t e r i a l - P r i c e a n d A v a i l a b i l i t y ................................. 3 3 B . I n d u s t r y S u p p o r t I n f o r m a t i o n .................................. 3 3 C . P a r t s N e c e s s a r y F o r E a c h A i r p l a n e.............................. 3 3 1 . K i t s / P a r t s : ......................................... 3 3 2 . P a r t s a n d M a t e r i a l s S u p p l i e d b y t h e O p e r a t o r :...................... 3 3 3 . P a r t s M o d i f i e d a n d R e i d e n t i f i e d : ............................. 3 3 4 . P a r t s R e m o v e d a n d N o t R e p l a c e d : ............................ 3 4 D . P a r t s N e c e s s a r y t o C h a n g e S p a r e s.............................. 3 4 E . S p e c i a l T o o l i n g - P r i c e a n d A v a i l a b i l i t y ............................. 3 4 F . S p e c i a l T o o l i n g N e c e s s a r y t o d o t h i s S e r v i c e B u l l e t i n ..................... 3 4 3 . A C C O M P L I S H M E N T I N S T R U C T I O N S ............................... 3 5 A . G E N E R A L I N F O R M A T I O N .................................. 3 5

B. WORK INSTRUCTIONS36

FIGURE 1: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITHOUT POCKETS) INSTALLATION I N S P E C T I O N....................................... 3 9 FIGURE 2: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITHOUT POCKETS) REMOVAL AND I N S P E C T I O N ...................................... 4 1 FIGURE 3: AFT ENGINE MOUNT, CENTER LINK (WITH POCKETS) INSTALLATION INSPECTION 45 FIGURE 4: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITH POCKETS) REMOVAL AND I N S P E C T I O N....................................... 4 7 F I G U R E5 : H A N G E R F I T T I N G , A D D I D E N T I F I C A T I O N M A R K S .................... 5 1 FIGURE 6: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITHOUT POCKETS), ADD I D E N T I F I C A T I O N M A R K S................................ 5 2

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ALERT ALERT FIGURE 7: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITH POCKETS), ADD I D E N T I F I C A T I O N M A R K S ................................. 5 3 FIGURE 8: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITHOUT POCKETS) AND ENGINE I N S T A L L A T I O N......................................5 4 FIGURE 9: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY (WITH POCKETS) AND ENGINE I N S T A L L A T I O N .....................................5 8

APPENDIX A: AFT ENGINE MOUNT, CENTER LINK ASSEMBLY REPORT FORM62

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ALERT ALERT Commercial Airplane Group 737

ALERTALERT Service Bulletin Number: 737-71A1462 Revision Transmittal Sheet Date: August 29, 2002 Revision 3 May 20, 2004 ATA System: 7121 SUBJECT: POWER PLANT - Engine Mounts - Aft Engine Mount, Link Assembly, Hanger Fitting, Inspection, Correction and Identification of Parts This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-03-01, Amendment 39-13025, is related to this service bulletin.

More work is necessary for airplanes that have not had an engine change since the new airplane was received from Boeing, do the Part 1 Inspection procedures unless the Part 1 Inspection or the Part 2 Part Mark procedures have been done.

No more work is necessary on airplanes that have had an engine change since the new airplane was received from Boeing, have done the Part 1 Inspection and Part 2 Part Mark procedures.

No airplanes have been added by Revision 3 of this service bulletin. The Revision 2 of this service bulletin included the airplanes effectivity that could be affected by this service bulletin.

REASON FOR REVISION Revision 3 is sent to tell operators that for the airplanes that have not had an engine change since the new airplane was received from Boeing, it is possible that some center links were incorrectly installed in an aft engine mount before the airplane was delivered. Before this revision, inspection of the aft engine mounts was necessary only for the airplanes that had an engine change after the new airplane was received from Boeing.

With the release of Revision 3 of this service bulletin, the Part 1 Inspection is applicable to all airplanes given in the effectivity of this service bulletin.

1. On Summary section, Background, paragraph 1.C., Reason and paragraph 1.D., Description, more information has been added to include the airplanes that have not had an engine change since the new airplane was received from Boeing.

2. On Summary section, Background, paragraph 1.C., Reason and paragraph 1.J., References, a new paragraph has been added to show the Boeing Service Related Problem information that is related to this service bulletin.

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3. On Summary section and paragraph 1.E., Compliance information, the paragraphs about Part 1 have been changed to include airplanes that have not had an engine change since the new airplane was received from Boeing. The paragraphs about Part 2 have been changed to give more information. All engine installed after 90 days has been changed to during the subsequent engine changes done after 90 days.

4. On paragraph 1.A., Planning Information, Effectivity, a group condition table has been added.

5. On paragraph 2.B., Industry Support Information, a warranty statement has been added for airplanes that have not had an engine change since the new airplane was received from Boeing.

6. On paragraph 2.C.3., Parts Modified and Reidentified table and Figure 5 work instruction table, Step 2, the part numbers for the hanger fitting 310A2031-23 and the hanger fitting assembly 310A2031-24 have been added.

7. On paragraph 3.B.,Part 1,2., the work instruction step has been changed to delete information about airplanes that have had an engine change after the airplane was delivered and during subsequent engine installations. The changed Step 2 make the step applicable to all airplanes and the same compliance information is already shown in the Compliance paragraphs.

8. On paragraph 3.B.,Part 1,3.e. and Part 2,1., the work instruction steps have been added for airplanes if do or not do the Part 1 and Part 2 Work Instructions at the same time.

9. On paragraph 3.B.,Part 1,4., the work instruction step has been added for airplanes that have found the aft engine mounts correctly installed.

10. On paragraph 3.B.,Part 2,4., the work instruction step has been added to close access. The note on the left, right and aft markings has been changed to a Caution note.

11. Figures 1 and 3 have been changed to show the left side view to agree with the note that said the best view is from the left side. The view was shown from the right side of the aft engine mount.

12. Figures 2 and 4 have been changed to delete the assembly and installation steps Steps 9 through 12. The same assembly and installation steps have been moved to the new Figures 8 and 9 for airplanes that possibly do Part 1 Correction and Part 2 part mark work instructions at the same time.

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 Original Issue: August 29, 2002 Revision 1: November 7, 2002 Revision 2: May 29, 2003 Revision 3: May 20, 2004

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ALERT ALERT Commercial Airplane Group 737

ALERTALERT Service Bulletin Number: 737-71A1462 Summary Date: August 29, 2002 Revision 3 May 20, 2004 ATA System: 7121 SUBJECT: POWER PLANT - Engine Mounts - Aft Engine Mount, Link Assembly, Hanger Fitting, Inspection, Correction and Identification of Parts

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Part 1 of this service bulletin was initially prepared to give instructions for operators to do a one-time inspection of all airplanes that have had an engine change since the airplane was delivered. It is necessary to do the inspection on all subsequent engine changes unless Part 2 marked engine mounts are installed.

In September 2003, an operator told Boeing that an airplane was found with a center link installed incorrectly on an aft engine mount. The operator also told Boeing that the airplane had not had an engine change since the new airplane was received from Boeing. As a result, it is necessary for airplanes that have not had an engine change since the new airplane was received from Boeing to do the Part 1 inspection on each of the aft engine mounts.

In October 2001, one operator told Boeing it was necessary to get clarification of manuals related to engine mount assembly and installation. After the initial help from Boeing, the operator reported that the aft engine mount center link assembly, P/N 310A2034-3, could have been reversed during overhaul assembly and subsequently installed on airplanes. The operator inspected all airplanes that had engine installations since the airplanes were delivered. Six reversed center links were found, which were immediately corrected. No damage was reported after visual inspection of the aft mount and local engine attachment was completed.

The operator found that no anomalies were reported during the aft engine mount installations or during the engine installations. It was found that some increase in force was necessary to install the pawl pins that attach the aft engine mount to the engine.

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August 29, 2002 Revision 3 May 20, 2004 737-71A1462 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8o f6 2 In December 2001, a second operator told Boeing about problems they had when they tried to close the thrust reversers after engine replacement. Visual inspection showed gap differences between the thrust reverser aft cowl and the primary exhaust sleeve on the two sides of the engine. The engine was lowered and the subsequent inspection found a reversed center link assembly, P/N 310A2034-7. After the center link was removed and installed correctly, the engine installation was completed satisfactorily.

Although the center link has an apparent symmetrical shape, there is a 0.2175 inch difference in the distances between the center bearing and each side bearing. Also, the two spherical bearings installed at each end are not the same bore diameter. The center link can be installed 180 degrees from the correct location (reversed) and still be attached to the engine with the pawl pins in the correct location. More force can be necessary to install the pins.

The reversed center link condition changes the structural loading of the aft engine mount interface with the engine. If not corrected, failure of the aft engine mount can occur. Also, the reversed center link installation causes a 0.174 inch displacement of the engine turbine rear frame to the right. The thrust reverser cowls are not easily closed if this condition exist.

Part 2 gives instructions to install the permanent marks on the aft engine mount, which, if installed, releases operators from the inspection requirements given in Part 1 of this service bulletin. The permanent marks identify the correct installation position of the hanger fitting assembly and the center link assembly of the aft engine mount.

Boeing Service Related Problem (SRP) 737-SRP-71-0035 is related to this service bulletin.

ACTION Part 1, open the engine thrust reversers and get access to the aft engine mount. Do an inspection of the aft engine mount to make sure that the center link assembly is correctly installed. If the center link assembly is incorrectly installed, correct the installation and report this to Boeing.

Part 2, get access and remove the aft engine mount. Mark the aft face of the hanger fitting with “L”, “R” and AFT” to identify the correct position for installation. Mark the aft face of the center link assembly with “L”, “R” and “AFT” to identify correct position for installation. Install the aft engine mount.

EFFECTIVITY 737-600/700/700C/800/900 airplanes. See Service Bulletin (SB) Paragraph 1.A.1 for effectivity.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-03-01, Amendment 39-13025, is related to this service bulletin.

Part 1, For airplanes that have had an engine change since the new airplane was received from Boeing, in 90 days or less from the initial release of SB 737-71A1462, Boeing recommends that operators do a one-time inspection of the aft engine mount and make sure of the correct installation of the center link assembly unless the mount is marked as given in the Part 2 of this service bulletin. If a reversed center link is found, the condition must be corrected before the next flight. If only one engine on an airplane has been replaced, it is only necessary to do an inspection of that engine.

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August 29, 2002 Revision 3 May 20, 2004 737-71A1462 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9o f6 2 Part 1: For airplanes that have not had an engine change since the new airplane was received from Boeing, in 90 days or less from the Revision 3 release of SB 737-71A1462, Boeing recommends that operators do a one-time inspection of the aft engine mount to make sure of the correct installation of the center link assembly.

If a reversed center link is found, the incorrect condition must be corrected before the next flight. No more new inspection is necessary if the aft engine mounts were inspected as shown in the initial, Revision 1 or Revision 2 of this service bulletin.

Part 1: For all subsequent engine changes on all airplanes, Boeing recommends operators do the Part 1 Inspection on each aft engine mount during each subsequent engine change until the marked aft engine mount is installed.

Part 2: For all airplanes that have had or have not had an engine change, Boeing recommends that operators do Part 2 part mark procedures if the engine mount is removed by the Part 1 Work Instructions, or during a subsequent usual engine maintenance task when the engine removal is necessary.

Part 2: Boeing recommends that during the subsequent engine changes done after 90 days from the release of SB 737-71A1462, Revision 2, install permanently marked aft engine mounts. All engine changes done in 90 days or less from the release of SB 737-71A1462, Revision 2, that do not have permanently marked aft engine mounts, must have an inspection done as given in the Part 1 Inspection.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin for airplanes that have had an engine change since the new airplane was received from Boeing.

Boeing warranty remedies are available for airplanes in warranty as of October 9, 2003 if the airplanes have not had an engine change since the new airplane was received from Boeing. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Manpower data for each engine position:

MATERIAL INFORMATION None.

PART 1 Total Task Hours Elapsed Hours Inspection 3.5 2.0 Removal and Installation 37.0 10.5 Inspection, Removal and Installation

40.5 12.5 PART 2 Total Task Hours Elapsed Hours Mark Aft Engine Mount 1.5 1.5

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ALERT ALERT FWD

FOR CORRECT INSTALLATION

INSPECT AFT ENGINE MOUNT PART 1:

HANGER FITTING

LINK ASSEMBLY AND

MARK THE CENTER PART 2:

V86787

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ALERT ALERT Commercial Airplane Group 737

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

Airplane models:

737-600 737-700 737-700C 737-800 737-900

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

GROUP CONDITION DESCRIPTION 1 - 737-600/-700/-700C/-800/-900 from Line 1 through 1277 1 737-600/-700/-700C/-800/-900 from Line 1 through 1277 airplanes that have had an engine change since the new airplane was received from Boeing, 2 737-600/-700/-700C/-800/-900 from Line 1 through 1277 airplanes that have had no engine change since the new airplane was received from Boeing,

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ALERT ALERT

AERO CONTRACTORS LTD (YAT) 1Y G 0 4 2

AIR ALGERIE (ALG) 1 YD101–YD107 YE301–YE305

AIR ASTANA (AKZ) 1 YA356–YA357 YC151

AIR BERLIN (BER) 1 YB201 YB203 YC051–YC070 YD151–YD155

AIR CHINA (BEJ) 1 YC941–YC951

AIR CHINA SOUTHWEST AIRLINES (XIN) 1 YC426–YC428 YE201–YE204

AIR EUROPA (ARE) 1 YC761–YC770 YC907 YD206–YD209

AIR MAURITANIE (MAR) 1 YA302

AIR NATIONAL GUARD (USK) 1 YG044 YG067 YG069

AIR PACIFIC (APC) 1 YA291 YC931–YC932

AIR SAHARA (SAQ) 1 YA253–YA254 YA731 YB204–YB205 YC901–YC902

AIR SENEGAL INTERNATIONAL (SNG) 1 YA683–YA684

AIR SEYCHELLES (ASY) 1 YA351

AIR SHAMROCK (SHI) 1Y G 0 1 6

ALASKA AIRLINES (ASA) 1 YA841–YA858 YD501–YD507

ALOHA AIRLINES (ALO) 1 YA607–YA608 YA610 YA614–YA615 YA627–YA629 YA732–YA733

AMERICAN AIRLINES (AAL) 1 YC801–YC877

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