# Boeing Special Attention Service Bulletin 737-53-1065: U.S. DOT/FAA - Service Bulletin-737-53-1065-03 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-6430; AD 2017-02-02 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Special Attention Service Bulletin 737-53-1065](https://openairdocs.org/service-documents/boeing/sb-737-53-1065.md) - Title as filed: U.S. DOT/FAA - Service Bulletin-737-53-1065-03 - Pages: 206 - PDF: https://openairdocs.org/files/sha256/d6/85/d685fcdc8c2cb09b7e1ba8f45134970bc5286f985109d3cc5ebfb9449c2f779c - Page: https://openairdocs.org/service-documents/boeing/sb-737-53-1065/file/d685fcdc8c2c ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 737 Service Bulletin SPECIAL ATTENTION Number: 737-53-1065 Original Issue: January 04, 1985 Revision 3: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Aft Skin - Inspection, Repair, and Skin Panel Replacement 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 © 1989 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 Unpublished Work.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: January 04, 1985 737-53-1065Revision 3: June 30, 2015 1 of 206 4.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 2 of 206 BOEING SERVICE BULLETIN 737-53-1065 BLANK PAGE ### Page 3 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 ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 8 D. Description .............................................. 2 9 E. Compliance .............................................. 3 0 F . A p p r o v a l ............................................... 4 0 G. Manpower .............................................. 4 1 H. Weight and Balance Changes .................................... 4 5 I. Electrical Load Data ......................................... 4 5 J . R e f e r e n c e s .............................................. 4 5 1. Existing Data: ......................................... 4 5 2. Data Supplied with this Service Bulletin: ........................... 4 6 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 7 K. Publications Affected ........................................ 4 8 L. Interchangeability and Intermixability of Parts ........................... 4 8 M. Software Accomplishment Summary ................................ 4 8 2. MATERIAL INFORMATION ........................................ 4 9 A. Material - Price and Availability ................................... 4 9 B. Industry Support Information .................................... 4 9 C. Parts Necessary for Each Airplane ................................. 5 0 1 . K i t s / P a r t s ............................................ 5 0 2. Parts and Materials Supplied by the Operator ........................ 6 8 3. Parts Modified and Reidentified ................................ 7 0 4. Parts Removed and Not Replaced .............................. 7 0 D. Parts Necessary to Change Spares ................................. 7 0 E. Special Tooling - Price and Availability ............................... 7 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 7 0 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 7 1 A. GENERAL INFORMATION ..................................... 7 1 B. WORK INSTRUCTIONS ....................................... 7 3 FIGURE 1: INSPECTION ZONES - LEFT SIDE BS 727 TO BS908, S-14L TO S-20L [Group 2-28] . . 86 FIGURE 2: INSPECTION ZONES - LEFT SIDE BS 727 TO BS908, S-20L TO S-25L [Group 2-28] . . 87 FIGURE 3: INSPECTION ZONES - LEFT SIDE BS 727 TO BS908, S-14L TO S-20L [Group 29-40] . 88 FIGURE 4: INSPECTION ZONES - LEFT SIDE BS 727 TO BS908, S-20L TO S-25L [Group 29-40] . 90 FIGURE 5: INSPECTION ZONES - LEFT SIDE BS 908 TO BS 1016, S-14L TO S-20L [Group 2-40] . 91 FIGURE 6: INSPECTION ZONES - LEFT SIDE BS 908 TO BS 1016, S-20L TO S-25L [Group 2-40] . 92 FIGURE 7: INSPECTION ZONES - RIGHT SIDE BS 727 TO BS 908, S-14R TO S-25R [Group 2-40] . 93 FIGURE 8: INSPECTION ZONES - RIGHT SIDE BS 908 TO BS 1016, S-14R TO S20R [Group 2-40] . 96 FIGURE 9: INSPECTION ZONES - RIGHT SIDE BS 908 TO BS 1016, S-20R TO S25R [Group 2-40] . 97 FIGURE 10: EXTERNAL OR INTERNAL INSPECTION [Group 2-40] ................... 9 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 3 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 4 FIGURE 11: INTERNAL INSPECTION [Group 2-40] ........................... 1 0 3 F I G U R E 1 2 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 0 7 F I G U R E 1 3 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 0 8 F I G U R E 1 4 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 0 9 F I G U R E 1 5 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 0 F I G U R E 1 6 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 1 F I G U R E 1 7 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 2 F I G U R E 1 8 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 3 F I G U R E 1 9 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 4 F I G U R E 2 0 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 5 F I G U R E 2 1 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 6 F I G U R E 2 2 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 7 F I G U R E 2 3 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 8 F I G U R E 2 4 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 1 9 F I G U R E 2 5 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 0 F I G U R E 2 6 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 1 F I G U R E 2 7 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 2 F I G U R E 2 8 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 3 F I G U R E 2 9 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 4 F I G U R E 3 0 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 5 F I G U R E 3 1 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 6 F I G U R E 3 2 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 7 F I G U R E 3 3 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 8 F I G U R E 3 4 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 2 9 F I G U R E 3 5 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 0 F I G U R E 3 6 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 1 F I G U R E 3 7 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 2 F I G U R E 3 8 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 3 F I G U R E 3 9 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 4 F I G U R E 4 0 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 5 F I G U R E 4 1 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 6 F I G U R E 4 2 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 7 F I G U R E 4 3 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 8 F I G U R E 4 4 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 3 9 F I G U R E 4 5 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 0 F I G U R E 4 6 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 1 F I G U R E 4 7 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 2 F I G U R E 4 8 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 3 F I G U R E 4 9 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 4 F I G U R E 5 0 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 5 F I G U R E 5 1 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 6 F I G U R E 5 2 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 7 F I G U R E 5 3 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 8 F I G U R E 5 4 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 4 9 F I G U R E 5 5 : T H I S F I G U R E W A S D E L E T E D A T R E V I S I O N 3 ...................... 1 5 0 FIGURE 56: TIME LIMITED SKIN REPAIR [Group 2-40] ......................... 1 5 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 4 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 5 FIGURE 57: OPTION 1 MODIFICATION OF PERMANENT REPAIR INSTALLED IN ACCORDANCE WITH REVISION 2 OF THIS SERVICE BULLETIN [Group 2-40] ................. 1 5 6 FIGURE 58: OPTION 2 MODIFICATION OF PERMANENT REPAIR INSTALLED IN ACCORDANCE WITH REVISION 2 OF THIS SERVICE BULLETIN [Group 2-40] ................. 1 6 1 FIGURE 59: OPTION 1 PERMANENT REPAIR INSTALLATION FOR TIME LIMITED REPAIRS INSTALLED IN ACCORDANCE WITH REVISION 2 OF THIS SERVICE BULLETIN [Group 2-40] . . . 167 FIGURE 60: OPTION 2 PERMANENT REPAIR INSTALLATION FOR TIME LIMITED REPAIRS INSTALLED IN ACCORDANCE WITH REVISION 2 OF THIS SERVICE BULLETIN [Group 2-40] . . . 172 FIGURE 61: OPTION 1 PERMANENT REPAIR INSTALLATION FOR AIRPLANES WITH A TIME LIMITED REPAIR INSTALLED WITH REVISION 3 OF THIS SERVICE BULLETIN [Group 2-40] . 178 FIGURE 62: OPTION 2 PERMANENT REPAIR INSTALLATION FOR AIRPLANES WITH A TIME LIMITED REPAIR INSTALLED IN ACCORDANCE WITH REVISION 3 OF THIS SERVICE BULLETIN [Group 2-40] .......................................... 1 8 3 FIGURE 63: POST REPAIR EXTERNAL LFEC INSPECTION OF OPTION 1 PERMANENT REPAIR [Group 2 - 4 0 ] .............................................. 1 8 9 FIGURE 64: POST REPAIR EXTERNAL LFEC INSPECTION OF OPTION 2 PERMANENT REPAIR [Group 2 - 4 0 ] .............................................. 1 9 1 APPENDIX A: SKIN PANEL INSTALLATION DRAWINGS ......................... 1 9 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 5 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 6 of 206 BOEING SERVICE BULLETIN 737-53-1065 BLANK PAGE ### Page 7 Commercial Airplanes 737 Service Bulletin SPECIAL ATTENTION Revision Transmittal SheetNumber: 737-53-1065Original Issue: January 04, 1985 Revision 3: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Aft Skin - Inspection, Repair, and Skin Panel Replacement This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-13-30, AD 89-09-03 and AD 90-06-02 are related to this service bulletin. The effective date of AD 2005-13-30 is August 1, 2005. The Federal Aviation Administration (FAA) will possibly release an additional AD related to this service bulletin. The AD will make the compliance tasks and times given in this service bulletin mandatory. More work is necessary on airplanes changed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin. Operators must do new inspection requirements and skin panel replacement in accordance with Revision 3 of this service bulletin. Inspections are not required on skin panels that have been replaced using production skin panels after 59,000 total flight cycles. If the operator has record that a skin panel was replaced with a production skin panel prior to 59,000 total flight cycles, contact The Boeing Company for work instructions and do the work. If the operator does not have record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, inspections and skin panel replacement are required on that skin panel in accordance with this service bulletin. The time limited repair has additional inspection requirements and two options to make the repair permanent. If the time limited repair was done in accordance with Revision 2 of this service bulletin, it must be made permanent in accordance with Revision 3 of this service bulletin. Additionally, if a permanent repair was done in accordance with Revision 2 of this service bulletin, it must be modified or replaced in accordance with Revision 3 of this service bulletin. Installation of the stiffener modification and the subsequent one time subsurface eddy current inspection is no longer terminating action for the repeat inspections. Operators that have installed the stiffener modification must continue to do the repeat inspection in that area in accordance with Revision 3 of this service bulletin. REASON FOR REVISION This revision is sent to provide new and additional inspection requirements, add requirement to replace skin panels, change compliance time requirements, change time limited repair and permanent repair requirements, remove the options to install stiffener modification, and change airplane grouping. The inspection areas have changed from three zones to two zones. In Revision 2, Zones 1, 2, and 3 consisted of bonded doublers with pockets fully chem-milled to the bond line. The new zones include all previously inspected areas from the Original Issue, Revision 1 or Revision 2 of this service bulletin and additional areas where cracking could be found. Due to the change in zone definition, inspection criteria has been changed to allow for early detection of cracks. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 7 of 206 ### Page 8 The Option of doing detailed inspections every 2,000 flight cycles from Revision 2 has been removed because of reliability issues at a reasonable inspection interval. In order to mitigate Widespread Fatigue Damage (WFD) concerns, compliance and inspection requirements have changed as shown in the following two tables. Revision 2 Compliance Summary Threshold/Repeat IntervalsInspection Zone 16,000/3,600 flight cycles (External Inspections) or 2,000 flight cycles (External Inspec- tions) Zone 1 (a) 16,000/4,500 flight cycles (External Inspections)Zone 2 (b) 16,000/4,500 flight cycles (External Inspections)Zone 3 (c) (a) Zone 1: Areas under the fairing which have a history of cracking. (b) Zone 2: Areas that have similar loading and structural configuration as Zone 1 and Zone 3 but have no history of cracks. (c) Zone 3: Areas outside of fairing with history of cracking. Revision 3 Compliance Summary Threshold/Repeat IntervalsInspection Zone 16,000/3,700 flight cycles (Internal or External Inspections)Zone 1 (a) 34,000/7,500 flight cycles (External Inspections)Zone 2 (b) (a) Zone 1: Skin/bonded doubler with the bonded doubler chem-milled to the bond line in the pocket. (b) Zone 2: Skin/bonded doubler with a chem-milled pocket thickness of 0.050 inches (bonded doubler par- tially chem-milled). Airplane grouping has been changed as follows: Airplane ModelRevision 3 GroupRevision 2 Group 737-10011 thru 7 737-200 Passenger18 thru 21 737-200 Passenger2 and 422 737-200 Passenger10 thru 1323 737-200 Passenger3, 5 thru 8, 14, 1524 737-200 Passenger925 737-200 Passenger16 thru 24, 26 thru 2826 737-200 Passenger2527 737-200 Cargo128 thru 34 737-200 Cargo2935 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 8 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 9 Airplane ModelRevision 3 GroupRevision 2 Group 737-200 Cargo3036 737-200 Cargo3137 737-200 Cargo3338 737-200 Cargo32 and 3539 737-200 Cargo34, 36 and 3740 737-200 Cargo3841 737-200 Cargo39 and 4042 These sections were changed: 1. Summary - BACKGROUND: Information updated, body panel table added and planning table added. 2. Summary - ACTION: Information updated. 3. Summary - COMPLIANCE: Federal Aviation Administration (FAA) Airworthiness Directive (AD) statement added. 4. Paragraph 1.A. Effectivity: Groups changed for new skin panel numbers. 5. Paragraph 1.C. Reason: Revision information added. 6. Paragraph 1.D. Description: Information and table updated. 7. Paragraph 1.E. Compliance: Compliance tables changed to incorporate Non-Destructive Inspections (NDI), revised threshold and grace times and new tables added for time limited repairs and skin panel replacement. 8. Paragraph 1.F. Approval: Information updated to show new AD's, new AD paragraph references and updated text. 9. Paragraph 1.G. Manpower: New tables added for new inspections. 10. Paragraph 1.H. Weight and Balance: Two tables added. 11. Paragraph 2.A. Material and Price Availability: Existing kits removed and new skin panel part locations added. 12. Paragraph 2.C. Parts Necessary for Each Airplane: Kits removed and new skin panel part number/groups added. 13. Paragraph 3.A. General Information: New notes added. 14. Paragraph 3.B. Work Instructions: Parts changed from Roman Numerals to Numeric. Part 1 Inspection updated for new inspection process, Part 5 Skin Panel Replacement added. 15. Figure 1 thru Figure 9 revised for new inspection areas/zones. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 9 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 10 16. Figure 10 and Figure 11 new graphic added to illustration and new information added to step tables. 17. Figure 12 thru Figure 54 deleted. 18. Figure 57 thru Figure 64 added. 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 January 04, 1985Original Issue: October 12, 1989Revision 1: April 19, 2001Revision 2: June 30, 2015Revision 3: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 10 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 11 Commercial Airplanes 737 Service Bulletin SPECIAL ATTENTION SummaryNumber: 737-53-1065Original Issue: January 04, 1985 Revision 3: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Aft Skin - Inspection, Repair, and Skin Panel Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. CONCURRENT REQUIREMENTS None. BACKGROUND Operators have reported wrinkling and cracks in the fuselage side skins in the area just aft of the main wheelwell. Typically the cracks are in the skin only and are adjacent to the longitudinal edges of the bonded waffle doubler. Some cracks have been found in the tearstraps and visible only from the interior. The skin cracks are caused by fatigue from cyclic shear stresses due to cyclic wrinkling of the skin. At skin panel locations from Station (STA) 727 to STA 1016 (S-14 L/R to S-25 L/R), the cyclic wrinkling of the skin could cause a condition where skin cracks could form along the longitudinal edges of the bonded doubler. If not corrected, such skin cracking could adversely affect the structural integrity of the airplane. Before 1990, the only reported cracking was in zone1 of group 2 airplanes in revision 1 of this bulletin. However, since 1990, there have been cracks reported in zone 2 of group 2 airplanes and cracks reported on group 1 airplanes both of revision 1 of this bulletin. Because of this, the inspection area for all groups has been increased. One operator reported a 737-200 airplane beyond line number 920 that had a crack in the new inspection area. As a result, 737-200 and 737-200C airplanes after line number 920 were added to the bulletin effectivity as group 26,27, 41 and 42 airplanes in revision 2. One operator reported cracks in the skin where reinforcing angles had been installed. These cracks likely existed, but were undetectable when the stiffeners were installed. As a result, additional inspections are required in areas that have been previously modified with stiffeners. Since the release of Revision 2 of this bulletin, Boeing have completed a Widespread Fatigue Damage (WFD) assessment. Also, chem mill step cracks have been discovered while completing inspections in accordance with Revision 2 of this bulletin. This service bulletin gives instructions for inspections, repair, and replacement of skin panels where cracking can occur between Stringer S-14 and Stringer S-25 and from STA 727 to STA 1016 on the left and right side of the airplane. The inspection in accordance with this service bulletin will allow early detection of cracks in the skin panels. The repair of cracks in accordance with this service bulletin will restore structural integrity of the skin panel. Replacement of the skin panels is terminating action for repetitive inspection at the locations where the skin panels were replaced using production skin panels on airplanes with more than 59,000 total flight cycles. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 11 of 206 ### Page 12 Section 46 lower lobe skin panels addressed in this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). NOTE: Skin Panel at BS 908 - BS 1016 (S-14R to S-20R) does not have to be replaced. Boeing Service Related Problem (SRP) 737-SRP-53-0413 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 Air- plane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/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 Group 1: Boeing endorses the new 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 1 (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 2-40: This service bulletin provides instructions for the inspection and repair of the skin panels between STA 727 and STA 1016 and between Stringers S-14 and S-25. This service bulletin also provides instructions for skin panel replacement. Skin panel replacement is required at the following locations: – STA 727 to STA 908, S-14L to S-20L – STA 727 to STA 908, S-20L to S-25L – STA 727 to STA 908, S-14R to S-20R – STA 727 to STA 908, S-20R to S-25R – STA 908 to STA 1016, S-14L to S-20L – STA 908 to STA 1016, S-20L to S-25L – STA 908 to STA 1016, S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 12 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 13 The effectivity is divided into 40 groups because of different skin panel assembly configurations. The areas that require inspection are those where the bonded doubler has pockets fully chem-milled to the bond line or pockets partially chem-milled to a combined skin and doubler thickness of 0.050 inches. Do the inspections as given in this service bulletin from STA 727 to STA 1016 and from Stringer S-14 to Stringer S-25. If any crack is found, do the repairs and repetitive inspection requirements in accordance with this service bulletin. Skin panel replacement is mandatory within the time specified in Paragraph 1.E., Compliance. EFFECTIVITY All 737-100/-200 and -200C Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s). COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-13-30, AD 89-09-03 and AD 90-06-02 are related to this service bulletin. The effective date of AD 2005-13-30 is August 1, 2005. The Federal Aviation Administration (FAA) will possibly release an additional 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 This Service Bulletin was first issued before October of 1994. Therefore, there is no warranty statement included in this revision. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Refer to Paragraph 2.A., Material - Price and Availability Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 13 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 14 (OCR) BOEING SERVICE BULLETIN 737-53-1065 STA 1016 INSPECTION, REPAIR AND S-14R SKIN PANEL REPLACEMENT S-25R TYPICAL EXISTING FRAME - EXISTING STRINGERS 727 • EXISTING SKIN STIFFENERS ABOVE STRINGER 20 (MAY EXIST ON PREVIOUSLY MODIFIED AIRPLANES) INBD C FRAME INSPECT SKIN FOR CRACKS, REPAIR IF CRACKING IS FOUND € STRINGER € STRINGER OUTBOARD VIEW OF SKIN (TYPICAL) 2406432 RIGHT SIDE SHOWN, LEFT SIDE SIMILAR Original Issue: January 04, 1985 Revision 3: June 30, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53-1065 Work - See page 1 for details. 14 of 206 ### Page 15 Commercial Airplanes 737 Service Bulletin SPECIAL ATTENTION Number: 737-53-1065 Original Issue: January 04, 1985 Revision 3: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Aft Skin - Inspection, Repair, and Skin Panel Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This service bulletin is for the airplane(s) shown below. Refer to Service Bulletin Index Document D6-19567, Part 3 for Airplane Variable Number, Line Number, and Serial Number data. Airplane Models DESCRIPTIONCONFIGURATIONGROUP 737-100/-200/-200C Airplanes with cold bonded skins with line numbers 1-291 -1 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P2810-P2816 -2 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P2817-P2821 -3 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3605-P3635 -4 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3636-P3738 but excluding the airplanes in Group 9 -5 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3947-P4143 but excluding the airplanes in Group 7, 8, and 14 -6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 15 of 206 ### Page 16 DESCRIPTIONCONFIGURATIONGROUP 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3951-P4091 but excluding the airplanes in Group 6, 8, and 14 -7 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3975-P4138 but excluding the airplanes in Group 6, 7, and 14 -8 737-200 Airplanes with unique skin panel assemblies and installations with basic numbers P3657, P3697, P3698, and P3699 -9 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3739-P3946 but excluding the airplanes in Group 11, 12, and 13 -10 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3787-P3941 but excluding the airplanes in Group 10, 12, and 13 -11 737-200 Airplanes with unique skin panel assembly and installation with basic number P3924 -12 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3812-P3934 but excluding the airplanes in Group 10, 11, and 12 -13 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P3990-P4142 but excluding the airplanes in Group 6, 7, and 8 -14 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4401-P4419 -15 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4144-P4209 but excluding the airplanes in Group 17, 22, 23, and 25 -16 737-200 Airplanes with unique skin panel assemblies and installations with basic numbers P4168, P4172, and P4174 -17 737-200 Airplanes with unique skin panel assemblies and installations with basic numbers P4215, P4216, P4217, and P4225 -18 737-200 Airplanes with unique skin panel assembly and installation with basic number P4229 -19 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 16 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 17 DESCRIPTIONCONFIGURATIONGROUP 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4230-P4352 but excluding the airplanes in Group 21 and 28 -20 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4250-P4289 but excluding the airplanes in Group 20 and 28 -21 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4145-P4207 but excluding the airplanes in Group 16, 17, 23, and 25 -22 737-200 Airplanes with unique skin panel assemblies and installations with basic numbers P4169 and P4205 -23 737-200 Airplanes with unique skin panel assembly and installation with basic number P4353 -24 737-200 Airplanes with unique skin panel assembly and installation with basic number P4200 -25 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4210-P4227 but excluding the airplanes in Group 18 -26 737-200 Airplanes with unique skin panel assembly and installation with basic number P4228 -27 737-200 Airplanes with unique skin panel assemblies and installations within and including basic numbers P4232-P4267 but excluding the airplanes in Group 21 and 28 -28 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8903-P8912 but excluding the airplanes in Group 30 -29 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8907 and P8909 -30 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8913-P8943 but excluding the airplanes in Group 33 -31 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8960, P8961, P8963, and P8964 -32 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 17 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 18 DESCRIPTIONCONFIGURATIONGROUP 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8914-P8945 but excluding the airplanes in Group 30 -33 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8959 and P8962 -34 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8946-P8958 but excluding the airplanes in Group 36 and Group 37 -35 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8948-P8955 but excluding the airplanes in Group 35 and Group 37 -36 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8952 and P8953 -37 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8965, P8966, P8967, and P8970 -38 737-200C Airplanes with unique skin panel assemblies and installations with basic numbers P8968 and P8969 -39 737-200C Airplanes with unique skin panel assemblies and installations within and including basic numbers P8971-P8978 -40 Airplane Models: 737-100, 737-200, 737-200C GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG302 - PG314 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 18 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 19 GroupVariable Number 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG583 2PG584 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 2PH001 2PH011 - PH013 3PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH742 3PH743 1PJ001 - PJ002 4PJ003 5PJ004 - PJ005 10PJ006 13PJ007 - PJ009 1PJ031 - PJ032 1PJ071 - PJ072 1PJ101 - PJ104 4PJ105 - PJ109 5PJ110 - PJ111 11PJ112 - PJ118 7PJ119 15PJ201 - PJ219 4PK026 - PK027 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 19 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 20 GroupVariable Number 5PK028 - PK029 4PK041 - PK042 5PK043 - PK053 5PK061 - PK067 9PK068 - PK070 5PK081 10PK082 5PK091 - PK093 10PK094 - PK099 5PK101 - PK103 5PK111 - PK120 5PK141 - PK146 10PK201 - PK204 5PK211 - PK212 10PK213 - PK214 6PK215 20PK216 - PK220 5PK221 10PK222 - PK223 5PK231 - PK232 10PK233 - PK239 6PK240 5PK241 5PK251 - PK258 5PK271 - PK273 6PK274 5PK281 10PK282 - PK289 5PK291 5PK301 - PK304 10PK305 - PK310 5PK311 - PK314 10PK315 - PK318 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 20 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 21 GroupVariable Number 5PK341 5PK351 - PK352 10PK353 - PK355 13PK356 - PK360 6PK361 5PK391 10PK431 - PK433 10PK451 - PK452 10PK461 - PK469 10PK495 10PK501 13PK502 - PK503 14PK504 10PK511 - PK513 8PK514 18PK515 25PK519 10PK521 - PK524 6PK525 20PK526 - PK528 10PK541 - PK552 6PK553 - PK560 10PK561 - PK562 8PK563 - PK564 20PK565 10PK581 10PK591 - PK599 10PK601 - PK602 6PK603 - PK606 14PK607 - PK610 10PK611 - PK615 8PK616 6PK617 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 21 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 22 GroupVariable Number 10PK621 - PK626 8PK627 6PK628 - PK637 10PK641 - PK642 13PK661 6PK662 - PK664 20PK665 - PK666 10PK671 - PK674 8PK675 - PK677 6PK678 - PK680 20PK681 10PK691 - PK693 6PK694 - PK697 10PK711 - PK716 10PK731 - PK741 11PK742 - PK749 21PK750 - PK765 11PK771 - PK775 7PK776 - PK779 7PK801 - PK802 17PK803 - PK804 7PK819 11PK820 - PK822 7PK823 - PK826 17PK827 11PK830 10PK861 8PK862 - PK863 13PK871 14PK872 - PK874 10PK881 - PK882 6PK883 - PK884 10PK901 - PK908 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 22 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 23 GroupVariable Number 6PK909 - PK920 8PK921 - PK932 20PK933 - PK938 6PK971 8PK972 - PK974 5PL001 10PL002 - PL018 6PL019 - PL025 16PL026 - PL028 6PL061 8PL081 8PL101 - PL113 6PL151 6PL171 - PL172 8PL201 - PL203 6PL221 10PL401 - PL405 8PL406 - PL408 14PL409 - PL410 8PL411 14PL412 8PL413 - PL415 16PL416 - PL417 13PL421 10PL441 10PL451 - PL452 6PL453 - PL454 20PL455 - PL456 6PL471 8PL491 14PL501 - PL506 8PL551 - PL562 6PL581 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 23 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 24 GroupVariable Number 14PL601 23PL602 - PL603 6PL611 16PL621 - PL623 20PL624 - PL626 14PL631 - PL632 1PL711 - PL712 1PL716 4PL717 5PL718 - PL725 4PL726 - PL728 5PL729 - PL735 4PL736 - PL742 5PL743 10PL744 6PL745 20PL746 - PL747 4PL756 9PL758 4PL761 - PL763 5PL764 - PL767 10PL768 - PL770 4PL781 - PL782 6PL783 - PL787 16PL788 4PL793 1PL801 - PL803 8PM001 - PM006 16PM016 - PM017 12PM021 6PM022 8PM023 6PM051 - PM056 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 24 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 25 GroupVariable Number 16PM057 - PM062 19PM063 20PM064 - PM066 14PM101 - PM110 22PM111 - PM119 14PM141 - PM142 20PM171 20PM181 20PM251 - PM255 20PM281 - PM283 14PN001 22PN002 16PN021 - PN035 18PN036 - PN038 20PN039 - PN043 16PN081 - PN086 16PN101 - PN112 20PN113 - PN117 26PN131 - PN144 27PN145 28PN146 - PN163 20PN401 - PN420 20PN431 - PN433 20PN451 - PN456 20PN471 - PN474 20PN481 20PN491 - PN493 20PN501 - PN502 20PN511 - PN512 24PN521 1PX071 1PX701 1PY001 - PY008 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 25 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 26 GroupVariable Number 1PY021 29PY022 1PY031 29PY036 - PY037 29PY046 - PY047 31PY048 30PY051 - PY052 33PY053 39PY056 - PY057 33PY101 - PY103 29PY111 - PY112 31PY113 29PY131 31PY132 - PY133 35PY134 - PY135 33PY141 - PY143 31PY151 - PY152 35PY153 32PY154 31PY156 - PY157 31PY161 - PY162 31PY166 31PY191 33PY201 33PY221 - PY222 36PY231 36PY241 - PY243 37PY244 37PY270 33PY271 - PY275 33PY281 33PY286 1PY301 - PY304 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 26 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 27 GroupVariable Number 1PY321 - PY323 1PY341 - PY346 1PY361 - PY362 1PY381 31PY401 40PY409 - PY410 31PY411 35PY421 32PY422 35PY441 35PY451 32PY461 - PY462 40PY463 40PY591 - PY595 33PY611 - PY612 36PY621 34PY631 34PY651 38PY671 - PY672 38PY721 38PY741 2. Spares Affected None. B. Concurrent Requirements None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 27 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 28 C. Reason Operators have reported wrinkling and cracks in the fuselage side skins in the area just aft of the main wheelwell. Typically the cracks are in the skin only and are adjacent to the longitudinal edges of the bonded waffle doubler. Some cracks have been found in the tearstraps and visible only from the interior. The skin cracks are caused by fatigue from cyclic shear stresses due to cyclic wrinkling of the skin. At skin panel locations from STA 727 to STA 1016 (S-14 L/R to S-25 L/R), the cyclic wrinkling of the skin could cause a condition where skin cracks could form along the longitudinal edges of the bonded doubler. If not corrected, such skin cracking could adversely affect the structural integrity of the airplane. Before 1990, the only reported cracking was in zone1 of group 2 airplanes in revision 1 of this bulletin. However, since 1990, there have been cracks reported in zone 2 of group 2 airplanes and cracks reported on group 1 airplanes both of revision 1 of this bulletin. Because of this, the inspection area for all groups has been increased. One operator reported a 737-200 airplane beyond line number 920 that had a crack in the new inspection area. As a result, 737-200 and 737-200C airplanes after line number 920 were added to the bulletin effectivity as group 26, 27, 41 and 42 airplanes in revision 2. One operator reported cracks in the skin where reinforcing angles had been installed. These cracks likely existed, but were undetectable when the stiffeners were installed. As a result, additional inspections are required in areas that have been previously modified with stiffeners. Since the release of Revision 2 of this bulletin, Boeing have completed a Widespread Fatigue Damage (WFD) assessment. Also, chem mill step cracks have been discovered while completing inspections in accordance with Revision 2 of this bulletin. This service bulletin gives instructions for inspections, repair, and replacement of skin panels where cracking can occur between Stringer S-14 and Stringer S-25 and from STA 727 to STA 1016 on the left and right side of the airplane. The inspection in accordance with this service bulletin will allow early detection of cracks in the skin panels. The repair of cracks in accordance with this service bulletin will restore structural integrity of the skin panel. Replacement of the skin panels is terminating action for repetitive inspection at the locations where the skin panels were replaced using production skin panels on airplanes with more than 59,000 total flight cycles. Section 46 lower lobe skin panels addressed in this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). Revision 1 of this bulletin was sent to provide the recommendations of the Aging Fleet 737 Structures Working Group. Revision 2 was sent to: – Remove the modification statement referring to the Aging Airplane Structural Modification Document D6-38505, Section 3 – Incorporate NSC 2 which added two new nondestructive test methods. One test is an Eddy Current inspection for cracks in the bonded doublers and the other test is an Eddy Current inspection to detect subsurface skin cracks. – Add new NDT inspection, Magneto Optical Imaging, as an alternative inspection to the Eddy Current Inspection for subsurface cracks. – Increase the inspection area. – Add an interim repair. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 28 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 29 Revision 3 is sent to provide new and additional inspection requirements, add requirement to replace skin panels, change compliance time requirements, change time limited repair and permanent repair requirements, remove the options to install stiffener modification, and change airplane grouping. D. Description Group 1: Boeing endorses the new 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 1 (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 2-40: This service bulletin provides instructions for the inspection and repair of the skin panels between STA 727 and STA 1016 and between Stringers S-14 and S-25. This service bulletin also provides instructions for skin panel replacement. Skin panel replacement is required at the following locations: – STA 727 to STA 908, S-14L to S-20L – STA 727 to STA 908, S-20L to S-25L – STA 727 to STA 908, S-14R to S-20R – STA 727 to STA 908, S-20R to S-25R – STA 908 to STA 1016, S-14L to S-20L – STA 908 to STA 1016, S-20L to S-25L – STA 908 to STA 1016, S-20R to S-25R The effectivity is divided into 40 groups because of different skin panel assembly configurations. The areas that require inspection are those where the bonded doubler has pockets fully chem-milled to the bond line or pockets partially chem-milled to a combined skin and doubler thickness of 0.050 inches. Do the inspections in accordance with this service bulletin between STA 727 and STA 1016 and between Stringers S-14 and S-25. If any crack is found, do the repairs and repetitive inspection requirements in accordance with this service bulletin. Skin panel replacement is mandatory within the time specified in Paragraph 1.E., Compliance. Revision 3 - More work is necessary on airplanes changed in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin. Operators must do new inspection requirements and skin panel replacement in accordance with Revision 3 of this service bulletin. Inspections are not required on skin panels that have been replaced using production skin panels on airplanes with 59,000 total flight cycles. If the operator has record that a skin panel was replaced with a production skin panel prior to 59,000 total flight cycles, contact The Boeing Company for work instructions and do the work. If the operator does not have record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, inspections and skin panel replacement are required on that skin panel in accordance with this service bulletin. The time limited repair has additional inspection requirements and two options to make the repair permanent. If the time limited repair was done in accordance with Revision 2 of this service bulletin, it must be made permanent in accordance with Revision 3 of this service bulletin. Additionally, if a permanent repair was done in accordance with Revision 2 of this service bulletin, it must be modified or replaced in accordance with Revision 3 of this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 29 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 30 Installation of the stiffener modification and the subsequent one time subsurface eddy current inspection is no longer terminating action for repeat inspections. Operators that have installed the stiffener modification must continue to do the repeat inspection in that area in accordance with Revision 3 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1: Affected Maintenance Zones ZoneModel 1-8, 2-18, 2-20737-100, 737-200, 737-200C Group 2-28: Affected Maintenance Zones ZoneModel 1-8, 2-18, 2-20737-200 Group 29-40: Affected Maintenance Zones ZoneModel 1-8, 2-18, 2-20737-200C E. Compliance Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-13-30, AD 89-09-03 and AD 90-06-02 are related to this service bulletin. The effective date of AD 2005-13-30 is August 1, 2005. The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Do the required actions in accordance with Paragraph 3.B., Work Instructions. NOTE: The Damage Tolerance Inspections specified in Table 3, Table 4, and Table 6 below may be used in support of compliance with 14 Code of Federal Regulations, Section 121.1109 or 129.109. Group 1: Boeing endorses the new 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 1 (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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 30 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 31 Group 2-40: Table 1: Skin Inspection Requirements - Areas Without Stiffener Modification: Repeat Interval (Not to Ex- ceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 4,500 flight cycles af- ter the effective date of AD 2005-13-30. Before 16,000 total flight cy- cles. Zone 1: Do an internal or external in- spection for cracks in accor- dance with PART 1: INSPEC- TION. Airplanes that have not had any inspec- tions done in accordance with Revision 2 of this ser- vice bulletin as of the is- sue date of Revision 3 of this service bulletin. (a) (c) (d) (e) (f) -Within 4,500 flight cycles af- ter the Revi- sion 3 date of this service bulletin. Before 34,000 total flight cy- cles. Zone 2: Do a Detailed Inspection for cracks in accordance with PART 1: INSPECTION. (b) (c) (d) (e) (f) -Within 3,600 flight cycles after the last inspection done in accor- dance with Revision 2 of this service bulletin. Zone 1: Do an internal or external in- spection for cracks in accor- dance with PART 1: INSPEC- TION. Airplanes that have had at least one in- spection done in accor- dance with Revision 2 of this service bulletin as of the issue date of Revi- sion 3 of this service bul- letin. (a) (c) (d) (e) (f) -Within 4,500 flight cycles af- ter the Revi- sion 3 date of this service bulletin. Before 34,000 total flight cy- cles. Zone 2: Do a Detailed Inspection for cracks in accordance with PART 1: INSPECTION. (b) (c) (d) (e) (f) OPTION 1: TIME LIMITED REPAIRAny crack found at a lo- cation inspect- ed in accor- dance with PART 1. -Before further flight.Repair all cracks using the time limited repair in accor- dance with PART 3: RE- PAIR. (g) OPTION 2: SRM REPAIR -Before further flight.Repair all cracks using the SRM repair in accordance with PART 3: REPAIR. (g) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 31 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 32 Group 2-40: Table 1: Skin Inspection Requirements - Areas Without Stiffener Modification: Repeat Interval (Not to Ex- ceed) Compliance Time (Whichever Occurs Later) ActionCondition 3,700 flight cycles. (g)-Zone 1:No crack found at a lo- cation inspect- ed in accor- dance with PART 1. Do an internal or external in- spection for cracks in accor- dance with PART 1: INSPEC- TION. (a) (c) (d) (e) (f) 7,500 flight cycles. (g)-Zone 2: Do a Detailed inspection for cracks in accordance with PART 1: INSPECTION. (b) (c) (d) (e) (f) (a) Zone 1: Skin/bonded doubler with bonded doubler chem-milled to the bond line in the pocket. (b) Zone 2: Skin/bonded doubler with a chem-milled pocket thickness of 0.050 inches (bonded doubler partially chem-milled). (c) It is not required to inspect the chem-mill steps under existing external repair doublers provided either: 1. The installed repair was approved by the FAA or by a Boeing company authorized represen- tative who was authorized by the FAA to make such findings, and the installed repair extends a minimum of three rows of fasteners on each side of the chem-mill line, Or 2. The external repair doubler satisfies the following: – The installed repair was approved by the FAA or by a Boeing company authorized rep- resentative who was authorized by the FAA to make such findings, and – The repair extends a minimum of 2 rows of 3/16 inch diameter fasteners on each side of the chem-mill step in the circumferential direction with 5-6D fastener spacing, and – The repair is similar to 737-100/200 SRM 53-30-3 Figure 48 with regard to fastener type, size, layout, and pitch, repair part thickness and material, and repair installation. (d) Internal inspections can only be done if it is not possible to do the external inspections of the chem- mill steps for cracks due to interference with external repair doublers or existing structure. The wing to body fairing must be removed to do external inspections. Do internal inspections in accordance with 737 NDT Manual Part 4, 53-30-05 and 737 NDT Manual Part 6, 53-30-22 using the pencil probe specified in the procedure in lieu of external inspections. It is optional to do 737 NDT Manual Part 4, 53-30-06 in lieu of 737 NDT Manual Part 4, 53-30-05 and 737 NDT Manual Part 6, 53-30-22. – If repair fasteners prevent 737 NDT Manual Part 4, 53-30-05 or 737 NDT Manual Part 4, 53-30- 06 from being done across the full length of the chem-mill step, then do one of the above inspec- tions where the probe will fit between the fasteners and also do 737 NDT Manual Part 6, 53-30- 22 using the pencil probe specified in the procedure along the full length of the chem-mill step. (e) If the operator has record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, contact The Boeing Company for work instructions, and do the work. If the operator does not have record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, inspections are required on that skin panel at the compliance time specified in this table. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 32 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 33 Group 2-40: Table 1: Skin Inspection Requirements - Areas Without Stiffener Modification: Repeat Interval (Not to Ex- ceed) Compliance Time (Whichever Occurs Later) ActionCondition (f) Inspections are not required on production skin panels that were replaced with production skin panels after 59,000 total flight cycles. (g) Accomplishment of PART 3: REPAIR is terminating action for repeat inspection requirements at the repaired locations only. Group 2-40: Table 2: Skin Inspection Requirements - Areas With Stiffener Modification Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 4,500 cy- cles after the ef- fective date of AD 2005-13-30. Before 16,000 total flight cy- cles. Zone 1: Do an internal or external inspection for cracks in accordance with PART 1: INSPECTION. (a) (b) (c) (d) (e) Airplanes that have not had any inspections done in accordance with Revision 2 of this service bulletin as of the issue date of Revi- sion 3 of this service bul- letin. -Within 4,500 cycles after last in- spection done in accordance with Revision 2 of this service bulletin. Zone 1: Do an internal or external inspection for cracks in accordance with PART 1: INSPECTION. (a) (b) (c) (d) (e) Airplanes that have had at least one inspection done in accordance with Revi- sion 2 of this service bul- letin as of the issue date of Revision 3 of this service bulletin. AND Have not accomplished the one time terminating action inspection in accordance with Revision 2 of this ser- vice bulletin. -Within 4,500 cycles after the Revi- sion 3 date of this service bulletin. Zone 1: Do an internal or external inspection for any crack in accordance with PART 1: INSPECTION. (a) (b) (c) (d) (e) Airplanes that have accom- plished the one time termi- nating action in accordance with Revision 2 of this ser- vice bulletin as of the issue date of Revision 3 of this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 33 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 34 Group 2-40: Table 2: Skin Inspection Requirements - Areas With Stiffener Modification Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition OPTION 1: TIME LIMITED REPAIRAny crack found at a loca- tion inspected in accor- dance with PART 1. -Before further flight.Repair all cracks usingthe time limited repair in accordance with PART 3: REPAIR. (f) OPTION 2: SRM REPAIR -Before further flight.Repair all cracks using the SRM repair in accor- dance with PART 3: RE- PAIR. (f) 3,700 flight cycles. (f) -Zone 1: Do an internal or external inspection for cracks in accordance with PART 1: INSPECTION. (a) (b) (c) (d) (e) No crack found at a loca- tion inspected in accor- dance with PART 1. (a) Zone 1: Skin/bonded doubler with bonded doubler chem-milled to the bond line in the pocket. (b) It is not required to inspect the chem-mill steps under existing external repair doublers provided either: 1. The installed repair was approved by the FAA or by a Boeing company authorized representative who was authorized by the FAA to make such findings, and the installed repair extends a mini- mum of three rows of fasteners on each side of the chem-mill line, Or 2. The external repair doubler satisfies the following: – The installed repair was approved by the FAA or by a Boeing company authorized repre- sentative who was authorized by the FAA to make such findings, and – The repair extends a minimum of 2 rows of 3/16 inch diameter fasteners on each side of the chem-mill step in the circumferential direction with 5-6D fastener spacing, and – The repair is similar to 737-100/200 SRM 53-30-3 Figure 48 with regard to fastener type, size, layout, and pitch, repair part thickness and material, and repair installation. (c) Internal inspections can only be done if it is not possible to do the external inspections of the chem-mill steps for cracks due to interference with external repair doublers or existing structure. The wing to body fairing must be removed to do external inspections. Do internal inspections in accordance with 737 NDT Manual Part 4, 53-30-05 and 737 NDT Manual Part 6, 53-30-22 using the pencil probe specified in the procedure in lieu of external inspections. It is optional to do 737 NDT Manual Part 4, 53-30-06 in lieu of 737 NDT Manual Part 4, 53-30-05 and 737 NDT Manual Part 6, 53-30-22. – If repair fasteners prevent 737 NDT Manual Part 4, 53-30-05 or 737 NDT Manual Part 4, 53-30-06 from being done across the full length of the chem-mill step, then do one of the above inspections where the probe will fit between the fasteners and also do 737 NDT Manual Part 6, 53-30-22 using the pencil probe specified in the procedure along the full length of the chem-mill step. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 34 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 35 Group 2-40: Table 2: Skin Inspection Requirements - Areas With Stiffener Modification Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (d) If the operator has record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, contact The Boeing Company for work instructions, and do the work. If the operator does not have record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, inspections are required on that skin panel at the compliance time specified in this table. (e) Inspections are not required on production skin panels that were replaced with production skin panels after 59,000 total flight cycles. (f) Accomplishment of PART 3: REPAIR is terminating action for repeat inspection requirements at the re- paired locations only. Group 2-40: Table 3: Post Repair Inspection and Modification of Time Limited Repair Installed in Accordance with Revision 2 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the installation of the time limited re- pair. (a) Do an external General Visual Inspection for loose or missing fasten- ers common to the re- paired areas in accor- dance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. All airplanes with time limit- ed repairs installed in accor- dance with Revision 2 of this service bulletin as of the issue date of Revision 3 of this service bulletin. -Within 4,500 flight cycles after the installation of time limited repair. (a) Zone 1: Do a Detailed inspection of the bonded doubler for disbond and a HFEC in- spection of the bonded doubler for cracks in ac- cordance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. (b) -Within 4,500 flight cycles after the installation of time limited repair. (a) Zone 2: Do a HFEC inspection of the bonded doubler for cracks in accordance with PART 6: POST REPAIR INSPECTION OF TIME LIMITED REPAIR. (c) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 35 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 36 Group 2-40: Table 3: Post Repair Inspection and Modification of Time Limited Repair Installed in Accordance with Revision 2 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Replace the loose or missing fastener in accor- dance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. Any loose or missing fasten- er is found. 3,000 flight cycles. (a) -Do a general visual in- spection for loose or missing fasteners com- mon to the repaired areas in accordance with PART 6: POST REPAIR IN- SPECTION OF TIME LIMITED REPAIR. 3,000 flight cycles. (a) -Do a general visual in- spection for loose or missing fasteners com- mon to the repaired areas in accordance with PART 6: POST REPAIR IN- SPECTION OF TIME LIMITED REPAIR. No loose or missing fasten- ers are found. -Before further flight.Contact The Boeing Company for work instruc- tions and do the work. Any disbonding or crack found. -Within 4,000 flight cycles af- ter the Revision 3 date of this service bulletin. Before 6,000 flight cycles af- ter the installa- tion of the time limited repair. Make the time limited re- pair permanent in accor- dance with PART 2: PERMANENT REPAIR INSTALLATION AND MODIFICATION. (a) Airplanes with a time limit- ed repair installed with less than 6,000 flight cycles since repair was installed at the Revision 3 date of this service bulletin and no disbond or crack found. -Within 10,000 flight cycles after the installation of the time limited repair. Make the time limited re- pair permanent in accor- dance with PART 2: PERMANENT REPAIR INSTALLATION AND MODIFICATION. (a) Airplanes with a time limit- ed repair installed with 6,000 flight cycles or more since repair was installed at the Revision 3 date of this service bulletin and no disbond or crack found. (a) Making the time limited repair permanent in accordance with PART 2 of this service bulletin is terminating action for the inspection requirement in this table. (b) Zone 1: Skin/bonded doubler with the bonded doubler chem-milled to the bond line in the pocket. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 36 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 37 Group 2-40: Table 3: Post Repair Inspection and Modification of Time Limited Repair Installed in Accordance with Revision 2 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Zone 2: Skin/bonded doubler with a chem-milled pocket thickness of 0.050 inches (bonded doubler par- tially chem-milled). Group 2-40: Table 4: Post Repair Inspection and Modification of Time Limited Repair Installed in Accordance with Revision 3 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 3,000 flight cycles after the installation of the time limited re- pair. (a) Do an external General Visual Inspection for loose or missing fasten- ers common to the re- paired areas in accor- dance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. All Airplanes with Time Limited Repairs installed in accordance with Revision 3. -Within 4,500 flight cycles after the installation of the time limited re- pair. (a) Zone 1: Do a Detailed inspection of the bonded doubler for disbond and a HFEC in- spection of the bonded doubler for cracks in ac- cordance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. (b) -Within 4,500 flight cycles after the installation of the time limited re- pair. (a) Zone 2: Do a HFEC inspection of the bonded doubler for cracks in accordance with PART 6: POST REPAIR INSPECTION OF TIME LIMITED REPAIR. (c) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 37 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 38 Group 2-40: Table 4: Post Repair Inspection and Modification of Time Limited Repair Installed in Accordance with Revision 3 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Replace the loose or missing fastener in accor- dance with PART 6: POST REPAIR INSPEC- TION OF TIME LIMITED REPAIR. Any loose or missing fasten- er is found. 3,000 flight cycles. (a) -Do a general visual in- spection for loose or missing fasteners com- mon to the repaired areas in accordance with PART 6: POST REPAIR IN- SPECTION OF TIME LIMITED REPAIR. 3,000 flight cycles. (a) -Do a general visual in- spection for loose or missing fasteners com- mon to the repaired areas in accordance with PART 6: POST REPAIR IN- SPECTION OF TIME LIMITED REPAIR. No loose or missing fasten- ers are found. -Before further flight.Contact The Boeing Company for work instruc- tions and do the work. Any disbonding or crack found. -Within 6,000 flight cycles after the installation of the time limited re- pair. Make the time limited re- pair permanent in accor- dance with PART 2: PERMANENT REPAIR INSTALLATION AND MODIFICATION. (a) No crack or disbond found. (a) Making the time limited repair permanent in accordance with PART 2 of this service bulletin is terminating action for the inspection requirement in this table. (b) Zone 1: Skin/bonded doubler with the bonded doubler chem-milled to the bond line in the pocket. (c) Zone 2: Skin/bonded doubler with a chem-milled pocket thickness of 0.050 inches (bonded doubler par- tially chem-milled). Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 38 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 39 Group 2-40: Table 5: Modification of Existing Time Limited Repairs previously made Permanent in Accordance with Revision 2 of this Service Bulletin. Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 4,000 flight cycles after the Revision 3 date of this service bulletin. Modify the existing perma- nent repair in accordance with PART 2: PERMA- NENT REPAIR INSTAL- LATION AND MODIFICA- TION. Airplanes with an existing time limited repair that had previously been made per- manent in accordance with Revision 2 of this service bulletin. Group 2-40: Table 6: Post Repair Inspection of Permanent Repairs Installed in Accordance with PART 2: POST REPAIR INSTALLATION AND MODIFICATION of Revision 3 of this Service Bulletin. Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 5,000 flight cycles after ac- complishment of PART 2: PERMA- NENT REPAIR INSTALLATION AND MODIFICATION, Option 1, in accordance with Revision 3 of this service bulletin. Do PART 7: POST RE- PAIR INSPECTION OF PERMANENT REPAIR. Airplanes with a permanent repair installed in accor- dance with PART 2: PER- MANENT REPAIR INSTAL- LATION AND MODIFICA- TION, Option 1. -Before further flight.Contact The Boeing Company for work instruc- tions and do the work. Any crack found. 5,000 flight cycles.-Do PART 7: POST RE- PAIR INSPECTION OF PERMANENT REPAIR. No crack found. -Within 60,000 flight cycles after accomplishment of PART 2: PERMANENT REPAIR INSTALLA- TION AND MODIFICATION, Op- tion 2, in accordance with Revision 3 of this service bulletin. Do PART 7: POST RE- PAIR INSPECTION OF PERMANENT REPAIR. Airplanes with a permanent repair installed in accor- dance with PART 2: PER- MANENT REPAIR INSTAL- LATION AND MODIFICA- TION, Option 2. -Before further flight.Contact The Boeing Company for work instruc- tions and do the work. Any crack found. 5,000 flight cycles.-Do PART 7: POST RE- PAIR INSPECTION OF PERMANENT REPAIR. No crack found. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 39 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 40 Group 2-40: Table 7 - Skin Panel Replacement: Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 6,000 flight cycles af- ter the Revision 3 date of this service bulletin. Before 60,000 total flight cy- cles, but not be- fore 59,000 total flight cycles. Do PART 8: SKIN PANEL REPLACEMENT. (a) (b) (c) All Airplanes. (a) Replace the following skin panels: – STA 727 to STA 908, S-14L to S-20L – STA 727 to STA 908, S-20L to S-25L – STA 727 to STA 908, S-14R to S-20R – STA 727 to STA 908, S-20R to S-25R – STA 908 to STA 1016, S-14L to S-20L – STA 908 to STA 1016, S-20L to S-25L – STA 908 to STA 1016, S-20R to S-25R (b) If the operator has record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, contact The Boeing Company for work instructions, and do the work. If the operator does not have record that a skin panel was replaced with a production skin panel before 59,000 total flight cycles, skin panel replacement is required at that location at the compliance time specified in this table. (c) Skin Panel Replacement is not required on production skin panels that were replaced with production skin panels after 59,000 total flight cycles. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) 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. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves accomplishment of the inspections, repairs, skin panel replacement, and compliance times defined in Revision 3 of this service bulletin as an alternative method of compliance (AMOC) to the requirements of paragraphs (a), (b), (c), (d), and (g) of Airworthiness Directive AD 2005-13-30. All provisions of AD 2005-13-30 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. Where SB 737-53-1065, Revision 3, specifies to contact Boeing for appropriate action, prior to further flight, repair using a method approved in accordance with paragraph (h) of AD 2005-13-30. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 40 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 41 G. Manpower The table below shows an estimate of the man-hours necessary to do this inspection and modification for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-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: NOTE: Boeing endorses the new 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 1 (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 2-15: EXTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 3.006.002Open Access 4.0516.204FIGURE 10 - Gener- al Visual Inspection 106.50426.004FIGURE 10 - Subsur- face Inspection 3.006.002Close Access 116.55454.20TOTAL FOR EACH AIRPLANE Group 16-28: EXTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 3.006.002Open Access 4.0516.204FIGURE 10 - Gener- al Visual Inspection Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 41 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 42 Group 16-28: EXTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 2.5510.204FIGURE 10 - De- tailed Inspection 83.40333.604FIGURE 10 - Subsur- face Inspection 3.006.002Close Access 96.00372.00TOTAL FOR EACH AIRPLANE Group 29-37: EXTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 3.006.002Open Access 3.8015.204FIGURE 10 - Gener- al Visual Inspection 100.55402.204FIGURE 10 - Subsur- face Inspection 3.006.002Close Access 110.35429.40TOTAL FOR EACH AIRPLANE Group 38-40: EXTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 3.006.002Open Access 3.8015.204FIGURE 10 - Gener- al Visual Inspection 2.5010.004FIGURE 10 - De- tailed Inspection 77.68310.704FIGURE 10 - Subsur- face Inspection 3.006.002Close Access 89.98347.90TOTAL FOR EACH AIRPLANE Group 2-15: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 80.85646.808Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 42 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 43 Group 2-15: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 38.70154.804FIGURE 11 - De- tailed Inspection 116.20464.804FIGURE 11 - HFEC Inspection 80.85646.808Close Access 316.601913.20TOTAL FOR EACH AIRPLANE Group 16-28: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 81.00648.008Open Access 30.30121.204FIGURE 11 - De- tailed Inspection 116.20464.804FIGURE 11 - HFEC Inspection 81.00648.008Close Access 308.501882.00TOTAL FOR EACH AIRPLANE Group 29-37: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 49.25394.008Open Access 36.50146.004FIGURE 11 - De- tailed Inspection 109.70438.804FIGURE 11 - HFEC Inspection 49.25394.008Close Access 244.701372.80TOTAL FOR EACH AIRPLANE Group 38-40: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 51.00408.008Open Access 28.20112.804FIGURE 11 - De- tailed Inspection Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 43 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 44 Group 38-40: INTERNAL INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 109.70438.804FIGURE 11 - HFEC Inspection 51.00408.008Close Access 239.901367.60TOTAL FOR EACH AIRPLANE TIME LIMITED REPAIR Elapsed HoursTask HoursNumber of PersonsTask 2.004.002Open Access 7.75 (a)15.50 (a)2FIGURE 56 2.004.002Close Access 11.7523.50TOTAL FOR EACH AIRPLANE (a) The time given is for one repair location. PERMANENT REPAIR Elapsed HoursTask HoursNumber of PersonsTask 2.004.002Open Access 2.004.004OPTION 1 (a) 15.5031.004OPTION 2 (a) 2.004.002Close Access (a)(a)TOTAL FOR EACH AIRPLANE (a) Total time will be dependent on the number and type of repair installed. POST REPAIR INSPECTION OF PERMANENT REPAIR Elapsed HoursTask HoursNumber of PersonsTask 3.003.001FIGURE 63 1.853.702FIGURE 64 (a)(a)TOTAL FOR EACH AIRPLANE (a) Total time will be dependent on the number and type of repair installed. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 44 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 45 H. Weight and Balance Changes Group 1: NOTE: Boeing endorses the new 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 1 (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 2-40: Change in Moment (Pound-Inch- es) Change in Weight (Pounds)Task --Skin Replacement NoneNoneLeft Side NoneNoneRight Side --Total Group 2-40: Change in Moment (Pound-Inch- es) Change in Weight (Pounds)Task --Time Limited Repair +2,650+3.5Between Station 727 and 747 +3,000+3.5Between Station 747 and 887 +3,470+3.5Between Station 887 and 1016 I. Electrical Load Data Not applicable. J. References 1. Existing Data: a. Boeing Service Bulletin 737-53A1177 b. Boeing Service Letter 737-SL-51-042 c. Boeing Service Related Problem (SRP) 737-SRP-53-0413 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-13-30, 89-09-03, 90-06-02 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 45 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 46 e. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-41-05, 20-43-03, 20-44-04, 20-50-01, 20-50-19 f. 737 Non-Destructive Testing (NDT) Manual Part 4, 53-30-05, Part 4, 53-30-06, Part 6, 51-00-00, Part 6, 53-30-00, Part 6, 53-30-19, Part 6, 53-30-22, Part 6, 53-30-23, Part 6, 53-30-25, Part 6, 53-30-39 g. 737-100/200 Aircraft Maintenance Manual (AMM) 25-21-00, 25-22-00, 25-27-100, 25-52-121 h. 737-100/200 Structural Repair Manual (SRM) 51-30-2, 51-30-8, 51-50-1, 53-30-3 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -A12SKIN PANEL INSTL S-14L TO S-25L, STATION 727 TO STATION 908 65-45774 -D13 -B14 -A15 -A16 -A17 --19 -C20 --21 --22 -CKPL --DLSKIN PANEL INSTL S-14L TO S-25L, STATION 727 TO STATION 908 65-45774#DL Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 46 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 47 ADCNDCN/REVSheetTitleDrawing No -B15SKIN PANEL INSTL S-14R TO S-25R, STA 727 TO STA 908 65-45775 -A16 -A17 -C18 -A19 -A20 -B21 -A22 --23 -B24 --25 --26 -CYPL --DLSKIN PANEL INSTL S-14R TO S-25R, STA 727 TO STA 908 65-45775#DL -A13SKIN PANEL INSTL S-4 TO S-25, LEFT SIDE, STA 908 TO STA 1016 65-45777 -A14 -AJPL --DLSKIN PANEL INSTL S-4 TO S-25, LEFT SIDE, STA 908 TO STA 1016 65-45777#DL -B15SKIN PANEL INSTL-AFT GALLEY DOOR, STA 908-STA 1016 S-4R - S-25R 65-45778 -DYPL --DLSKIN PANEL INSTL-AFT GALLEY DOOR, STA 908-STA 1016 S-4R - S-25R 65-45778#DL -D12SKIN PANEL INSTL S-4L TO S-25L, STA 908 TO STA 1016 65-52988 -B13 -B15 -DPPL --DLSKIN PANEL INSTL S-4L TO S-25L, STA 908 TO STA 1016 65-52988#DL 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Number Title 65-52988 Skin Panel Instl. S-4L to S-25L, STA 908 to STA 1016 65-52988 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 47 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 48 TitleDrawing Number Skin Panel Instl. S-14L to S-25L, STA 727 to STA 90865-45774 Skin Panel Instl. S-14R to S-25R, STA 727 to STA 90865-45775 Skin Panel Instl. S-4 to S-25, Left Side, STA 908 to STA 101665-45777 Skin Panel Instl. Aft Galley Door, STA 908 to STA 1016, S-4R to S-25R 65-45778 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-SectionPublication 53-30737 Structural Repair Manual 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/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. DTI requirements for the structure affected are contained in 737-100/-200 SRM 53-30-3 Figure 48, for the SRM repair. The time limited repair is considered a category "C" repair that must be modified within the compliance time given in Paragraph 1.E., Compliance. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin, for the time limited repair after it has been made permanent. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 48 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 49 2. MATERIAL INFORMATION A. Material - Price and Availability 1. Group 1: Boeing endorses the new 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 1 (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. 2. Group 2-40: For skin panels in the following locations: – STA 727 to STA 908, S-14L to S-20L – STA 727 to STA 908, S-20L to S-25L – STA 727 to STA 908, S-14R to S-20R – STA 727 to STA 908, S-20R to S-25R – STA 908 to STA 1016, S-14L to S-20L – STA 908 to STA 1016, S-20L to S-25L – STA 908 to STA 1016, S-20R to S-25R a. The Boeing Company can supply the parts shown in Paragraph 2.C., Parts Necessary for Each Airplane for the skin panel locations shown above. Operators are encouraged to share schedule requirements with The Boeing Company for incorporation of the service bulletin. Contact The Boeing Company for ROLT and pricing information. NOTE: Due to the nature of the skin panel replacement, extensive coordination is required. Operators are encouraged to share scheduling requirements with The Boeing Company and to contact The Boeing Company for replacement part information as soon as possible. Contact The Boeing Company for ROLT and pricing information for the parts shown in Paragraph 2.A., Material - Price and Availability. 3. The parts are subject to the terms and conditions of The Boeing Company standard purchase order acknowledgement. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: a. Order on-line via ATA Spec 2000 or Boeing Part Page b. Fax to (206) 662-7145 c. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA B. Industry Support Information This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether the operator previously filed a warranty claim with Boeing on this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 49 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 50 C. Parts Necessary for Each Airplane 1. Kits/Parts a. To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability. Group 1: NOTE: Boeing endorses the new 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 1 (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 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y550 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y559 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y573 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165-45775Y571 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y564 S-14L to S-20L Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 50 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 51 Group 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y559 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y585 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165-45775Y571 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 4: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y550 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y554 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y101 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 51 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 52 Group 5: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y564 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y101 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 6-7: 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 LocationNameQTYPart Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y564 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y95 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 52 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 53 Group 6-7: 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 LocationNameQTYPart Number STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 8: 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 LocationNameQTYPart Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y52 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C80736Y830 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y95 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 9: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y564 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 53 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 54 Group 9: 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 LocationNameQTYNew Part Number STA 908 to STA 1016 New Skin Panel As- sembly 165-45777Y61 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165-45777Y520 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y101 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 10-11: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y43 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y101 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 54 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 55 Group 12: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y43 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y546 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y101 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 13: 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 LocationNameQTYPart Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y43 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y570 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y102 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 55 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 56 Group 13: 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 LocationNameQTYPart Number STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 14: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y52 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y91 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y95 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y104 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 15: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y564 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165-45774Y570 S-20L to S-25L Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 56 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 57 Group 15: 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 LocationNameQTYNew Part Number STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y134 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y137 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165-45775Y581 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y102 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 16-17: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C80736Y830 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 57 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 58 Group 18: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C80736Y830 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y132 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 19-21: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C80736Y830 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y73 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 58 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 59 Group 19-21: 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 LocationNameQTYNew Part Number STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 22-23: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y91 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y63 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y104 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 24: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y91 S-20L to S-25L Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 59 of 206 BOEING SERVICE BULLETIN 737-53-1065 ### Page 60 Group 24: 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 LocationNameQTYNew Part Number STA 908 to STA 1016 New Skin Panel As- sembly 165-52988Y73 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C80736Y834 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C36745Y104 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Group 25: 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 LocationNameQTYNew Part Number STA 727 to STA 908New Skin Panel As- sembly 165-45774Y63 S-14L to S-20L STA 727 to STA 908New Skin Panel As- sembly 165C80736Y830 S-20L to S-25L STA 908 to STA 1016 New Skin Panel As- sembly 165-45777Y61 S-14L to S-20L STA 908 to STA 1016 New Skin Panel As- sembly 165C36745Y122 S-20L to S-25L STA 727 to STA 908New Skin Panel As- sembly 165C36745Y96 S-14R to S-20R STA 727 to STA 908New Skin Panel As- sembly 165C80736Y827 S-20R to S-25R STA 908 to STA 1016 New Skin Panel As- sembly 165-45778Y85 S-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 04, 1985 737-53-1065Revision 3: June 30, 2015 60 of 206 BOEING SERVICE BULLETIN 737-53-1065 The text continues at https://openairdocs.org/service-documents/boeing/sb-737-53-1065/file/d685fcdc8c2c.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.