Boeing Special Attention Service Bulletin 737-53-1287: Revision 1, text

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION Number: 737-53-1287 Original Issue: March 11, 2009 Revision 1: November 15, 2010 ATA System: 5331 2321 SUBJECT: FUSELAGE - Skin - Skin Cracking Under the Number 3 VHF Antenna - Inspection, Repair and Preventive Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

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Table of Contents

Revision Transmittal Sheet7

Summary9

1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3

1. Airplanes ............................................ 1 3

2. Spares Affected ........................................ 2 3 B. Concurrent Requirements ...................................... 2 3 C. Reason ................................................ 2 4 D. Description .............................................. 2 5 E. Compliance .............................................. 2 6 F. Approval ............................................... 3 9 G. Manpower .............................................. 3 9 H. Weight and Balance Changes .................................... 4 7 I. Electrical Load Data ......................................... 4 7 J. References .............................................. 4 8

1. Existing Data .......................................... 4 8

2. Data supplied with this Service Bulletin ............................ 4 8

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 4 9 K. Publications Affected ........................................ 4 9 L. Interchangeability and Intermixability of Parts ........................... 5 0

2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 1 C. Parts Necessary For Each Airplane ................................. 5 1

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

2. Parts and Materials Supplied by the Operator ........................ 5 1

3. Parts Modified and Reidentified ................................ 6 1

4. Parts Removed and Not Replaced .............................. 6 1 D. Parts Necessary to Change Spares ................................. 6 2 E. Special Tooling - Price and Availability ............................... 6 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 2

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 3 A. GENERAL INFORMATION ..................................... 6 3 B. WORK INSTRUCTIONS ....................................... 6 3 FIGURE 1: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR COVER PLATE NOT REMOVED [Group 1, Configuration 1-2; Group 2, Configuration 1-2; Group 5] . 74 FIGURE 2: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR COVER PLATE NOT REMOVED [Group 3, 6] ............................. 7 6 FIGURE 3: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR COVER PLATE NOT REMOVED [Group 4] .............................. 7 8 FIGURE 4: NUMBER 3 VHF ANTENNA LOCATION - COVER PLATE REMOVAL [Group 1-4, 6, Configuration 2 ] ................................................ 8 0 FIGURE 5: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR THE COVER PLATE REMOVED [Group 1, Configuration 1-2; Group 2, Configuration 1-2] ....... 8 2 FIGURE 6: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR THE COVER PLATE REMOVED [Group 3, 6] ................................ 8 4

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FIGURE 7: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA OR THE COVER PLATE REMOVED [Group 4] ................................. 8 6 FIGURE 8: NUMBER 3 VHF ANTENNA - EXTERNAL INSPECTION WITH THE ANTENNA REMOVED [Group 5] ............................................ 8 8 FIGURE 9: NUMBER 3 VHF ANTENNA - INTERNAL INSPECTION [Group 1-2, Configuration 1; Group 5] .................................................. 9 0 FIGURE 10: NUMBER 3 VHF ANTENNA - INTERNAL INSPECTION [Group 3, 6, Configuration 1] . . 93 FIGURE 11: NUMBER 3 VHF ANTENNA - INTERNAL INSPECTION [Group 4, Configuration 1] .... 9 6 FIGURE 12: NUMBER 3 VHF ANTENNA LOCATION - COVER PLATE INSTALLATION [Group 1-4, 6, Configuration 2] ......................................... 9 9 FIGURE 13: NUMBER 3 VHF ANTENNA LOCATION - REPAIR PREPARATION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] ............................... 1 0 1 FIGURE 14: NUMBER 3 VHF ANTENNA LOCATION - REPAIR INSTALLATION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] ............................... 1 0 8 FIGURE 15: NUMBER 3 VHF ANTENNA LOCATION - REPAIR PREPARATION [Group 3] ...... 1 1 2 FIGURE 16: NUMBER 3 VHF ANTENNA LOCATION - REPAIR INSTALLATION [Group 3] ...... 1 1 9 FIGURE 17: NUMBER 3 VHF ANTENNA LOCATION - REPAIR PREPARATION [Group 4] ...... 1 2 3 FIGURE 18: NUMBER 3 VHF ANTENNA LOCATION - REPAIR INSTALLATION [Group 4] ...... 1 3 0 FIGURE 19: NUMBER 3 VHF ANTENNA LOCATION - REPAIR PREPARATION [Group 6] ...... 1 3 4 FIGURE 20: NUMBER 3 VHF ANTENNA LOCATION - REPAIR INSTALLATION [Group 6] ...... 1 4 1 FIGURE 21: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - PREPARATION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] .................. 1 4 5 FIGURE 22: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSPECTION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] ...................... 1 5 2 FIGURE 23: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - ANTENNA SUPPORT STRUCTURE INSTALLATION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] . 156 FIGURE 24: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSTALLATION [Group 1, Configuration 1-2; Group 2, Configuration 1-2] .................. 1 6 3 FIGURE 25: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - PREPARATION [Group 3] ............................................ 1 6 5 FIGURE 26: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSPECTION [Group 3 ] ................................................ 1 7 2 FIGURE 27: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - ANTENNA SUPPORT STRUCTURE INSTALLATION [Group 3] .......................... 1 7 6 FIGURE 28: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSTALLATION [Group 3] ............................................ 1 8 3 FIGURE 29: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - PREPARATION [Group 4] ............................................ 1 8 5 FIGURE 30: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSPECTION [Group 4 ] ................................................ 1 9 2 FIGURE 31: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - ANTENNA SUPPORT STRUCTURE INSTALLATION [Group 4] .......................... 1 9 6 FIGURE 32: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSTALLATION [Group 4] ............................................ 2 0 3 FIGURE 33: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - PREPARATION [Group 6] ............................................ 2 0 5 FIGURE 34: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSPECTION [Group 6 ] ................................................ 2 1 2

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FIGURE 35: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - ANTENNA SUPPORT STRUCTURE INSTALLATION [Group 6] .......................... 2 1 6 FIGURE 36: NUMBER 3 VHF ANTENNA LOCATION - PREVENTIVE MODIFICATION - INSTALLATION [Group 6] ............................................ 2 2 3 FIGURE 37: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITH AN ANTENNA INSTALLED [Group 1-2, Configuration 1] .............. 2 2 5 FIGURE 38: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITHOUT AN ANTENNA INSTALLED [Group 1-2, Configuration 2] ........... 2 2 8 FIGURE 39: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITH AN ANTENNA INSTALLED [Group 3, Configuration 1] ............... 2 3 0 FIGURE 40: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITHOUT AN ANTENNA INSTALLED [Group 3, Configuration 2] ............. 2 3 3 FIGURE 41: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITH AN ANTENNA INSTALLED [Group 4, Configuration 1] ............... 2 3 5 FIGURE 42: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITHOUT AN ANTENNA INSTALLED [Group 4, Configuration 2] ............. 2 3 8 FIGURE 43: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITH AN ANTENNA INSTALLED [Group 6, Configuration 1] ............... 2 4 0 FIGURE 44: NUMBER 3 VHF ANTENNA LOCATION - SUPPLEMENTAL INSPECTION ON AIRPLANES WITHOUT AN ANTENNA INSTALLED [Group 6, Configuration 2] ............. 2 4 3 APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN. 245

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 737-53-1287Original Issue: March 11, 2009 Revision 1: November 15, 2010 ATA System: 5331 2321 SUBJECT: FUSELAGE - Skin - Skin Cracking Under the Number 3 VHF Antenna - Inspection, Repair and Preventive Modification This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.

NOTE: The method for accomplishing internal frame inspections is changed in this revision. New and repeat inspections must be accomplished in accordance with Revision 1 of this Service Bulletin.

REASON FOR REVISION This revision is sent to give instructions for the repair and preventive modification of the skin at the number 3 VHF antenna location.

The following sections are changed:

1. The Summary Action section is updated.

2. The summary illustration is updated.

3. Paragraph 1.A., Effectivity - 737-400 airplanes are moved from Group 3 to new Group 6. A new Group 7 is added. Group 2 airplanes before line number 292 are moved to Group 7.

4. Paragraph 1.C., Reason is updated.

5. Paragraph 1.D., Description is updated.

6. Paragraph 1.E., Compliance - A compliance table for Group 4 is added. A table for supplemental inspection information is also added.

7. Paragraph 1.G., Manpower - The manpower information is updated.

8. Paragraph 1.J.1., Existing Data - Non-Destructive Testing (NDT) and Structural Repair Manual (SRM) references are added.

9. Paragraph 1.J.2., Data supplied with this Service Bulletin - Installation drawings are added.

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10. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added.

11. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Parts are added.

12. Paragraph 3.A., General Information - A note about fastener specification is added.

13. Paragraph 3.B., Work Instructions - Repair, preventive modification and supplemental inspection instructions are added.

14. Figures 13 to 44 are added.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY March 11, 2009Original Issue:

November 15, 2010Revision 1:

Original Issue: March 11, 2009 737-53-1287Revision 1: November 15, 2010 8 of 250 BOEING SERVICE BULLETIN 737-53-1287

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 737-53-1287Original Issue: March 11, 2009 Revision 1: November 15, 2010 ATA System: 5331 2321 SUBJECT: FUSELAGE - Skin - Skin Cracking Under the Number 3 VHF Antenna - Inspection, Repair and Preventive Modification BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND This service bulletin is sent to inspect the skin and surrounding structure for cracking under the number 3 VHF antenna. If the work given in this service bulletin is not done, then cracking in the skin or surrounding structure could remain undetected. Continued operation with undetected cracks could result in crack growth, possibly leading to separation of the antenna from the airplane, and rapid depressurization.

The number 3 VHF antenna is located on the lower external surface of the airplane at Buttock Line (BL) 0.0, aft of the main landing gear wheel well.

In May 2006 one operator reported a 15 inch longitudinal crack in the skin near BL 0.0 just forward of the number 3 VHF antenna cutout, running forward. The first 14 inches of the crack was hidden beneath the number 3 VHF antenna. Boeing has received five other reports of skin cracks between 1.5 and 3 inches in length in the same area. The reports also indicated that the main antenna support channel and other support structure were cracked.

The earliest reported cracking occurred at 18,289 total flight cycles. The reported cracks were caused by dynamic loading of the number 3 VHF antenna due to extended main landing gear turbulence.

Accomplishment of this service bulletin will make sure that any crack under the number 3 VHF antenna is detected and repaired before it reaches a critical length. A support fitting to stop cracks developing in the skin at the number 3 VHF antenna location is installed in production on airplanes from line 2791.

Boeing Service Related Problem (SRP) 737-SRP-53-0313 is related to this service bulletin.

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ACTION (PRR 35005-293RS) Group 1-4, Configuration 1; Group 5; Group 6, Configuration 1:

Get internal access to the number 3 VHF antenna support structure. Do an internal detailed inspection of the antenna support structure, surrounding frames, stringers and skin for cracking or corrosion. Do an external detailed inspection and High Frequency Eddy Current (HFEC) inspection of the skin for cracking. If any crack is found in the skin, install a repair. If no cracking is found, repeat the inspections or install a preventive modification. If any crack is found in the antenna support structure, surrounding frames or stringers, contact Boeing for repair instructions and do the repair. If corrosion is found install a repair or contact Boeing for repair instructions and do the repair.

Group 1-4, 6, Configuration 2:

If a number 3 VHF antenna was previously installed, or it is unknown if the antenna was previously installed, accomplish detailed inspections of the skin until the cover plate is removed from the number 3 VHF antenna location. With the cover plate removed, do a one time external detailed inspection and a HFEC inspection of the skin for cracking. If any crack is found, install a repair. If no cracking is found install the cover plate at the number 3 VHF antenna location. If records show that a number 3 VHF antenna has never been installed then no work is necessary.

If a repair or preventive modification is installed as given in this service bulletin, do supplemental Low Frequency Eddy Current (LFEC) inspections in the skin at fastener locations common to the doubler; do external detailed inspections of the doubler, tripler and skin and internal detailed inspections of the antenna support structure and skin for cracking. Do HFEC inspections for cracking in the frames. If any crack is found, contact Boeing for repair instructions and do the repair.

Group 1-2, Configuration 3:

No work is necessary.

Group 7:

Contact Boeing for the inspection, repair and preventive modification instructions.

EFFECTIVITY 737-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and repair given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower .

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MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 737-53-1287 1 INSPECTION AREA

TYPICAL

SKIN CRACK

ANTENNA TWO INCHES

FOOTPRINT ALL AROUND SEE SKIN AND

TYPICAL

SKIN CRACK

AREA OF REMOVED

SEALANT (TYPICAL) WITH THE NUMBER 3 VHF ANTENNA

OR COVER PLATE REMOVED, DO AN EXTERNAL INSPECTION OF THE SKIN FWD < FOR CRACKING. IF ANY CRACK IS FOUND, INSTALL A REPAIR.

DO AN INTERNAL INSPECTION FOR CRACKING OR CORROSION IN THE

SKIN, ANTENNA SUPPORT STRUCTURE, SURROUNDING FRAMES AND STRINGERS. IF ANY CRACK IS FOUND IN THE SKIN, INSTALL A REPAIR.

IF ANY CRACK OR CORROSION IS FOUND IN THE ANTENNA SUPPORT

STRUCTURE, SURROUND FRAMES AND STRINGERS, CONTACT BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR.

DO A DETAILED INSPECTION AND A

HFEC SURFACE INSPECTION OF THE

SKIN FOR CRACKING AROUND THE ANTENNA BASE AND SEALANT. NUMBER 3 IF ANY CRACK IS FOUND, INSTALL FWD < VHF ANTENNA 1496973 A REPAIR. B Original Issue: March 11, 2009 Revision 1: November 15, 2010 737-53-1287

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