Boeing Special Attention Service Bulletin 737-53-1315: Revision 1, text

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION Number: 737-53-1315 Original Issue: July 29, 2011 Revision 1: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Skin - Station 727 to 1016 - Aft Skin Inspection, Repair and 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:

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: July 29, 2011 737-53-1315Revision 1: June 30, 2015 1 of 102

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Original Issue: July 29, 2011 737-53-1315Revision 1: June 30, 2015 2 of 102 BOEING SERVICE BULLETIN 737-53-1315

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Table of Contents

Revision Transmittal Sheet5

S u m m a r y9

1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3

1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F . A p p r o v a l ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 6 I. Electrical Load Data ......................................... 2 6 J . R e f e r e n c e s .............................................. 2 6

1. Existing Data: ......................................... 2 6

2. Data Supplied with this Service Bulletin: ........................... 2 7

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 8 K. Publications Affected ........................................ 2 8 L. Interchangeability and Intermixability of Parts ........................... 2 9 M. Software Accomplishment Summary ................................ 2 9

2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 2 C. Parts Necessary for Each Airplane ................................. 3 2 1 . K i t s / P a r t s ............................................ 3 2

2. Parts and Materials Supplied by the Operator ........................ 3 4

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

4. Parts Removed and Not Replaced .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: INSPECTION ZONES - LEFT SIDE [Group 1-4] ....................... 5 0 FIGURE 2: INSPECTION ZONES - RIGHT SIDE [Group 1-4] ...................... 5 3 FIGURE 3: INSPECTION ZONES - LEFT SIDE [Group 5-6] ....................... 5 6 FIGURE 4: INSPECTION ZONES - RIGHT SIDE [Group 5-6] ...................... 5 8 FIGURE 5: EXTERNAL OR INTERNAL INSPECTION .......................... 6 0 FIGURE 6: INTERNAL INSPECTION ................................... 6 3 FIGURE 7: TIME LIMITED REPAIR .................................... 6 6 FIGURE 8: OPTION 1 PERMANENT REPAIR INSTALLATION FOR TIME LIMITED REPAIRS INSTALLED IN ACCORDANCE WITH ORIGINAL ISSUE OF THIS SERVICE BULLETIN ........ 7 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 9: OPTION 2 PERMANENT REPAIR INSTALLATION FOR TIME LIMITED REPAIRS INSTALLED IN ACCORDANCE WITH ORIGINAL ISSUE OF THIS SERVICE BULLETIN ........ 7 6 FIGURE 10: OPTION 1 PERMANENT REPAIR INSTALLATION FOR AIRPLANES WITH A TIME LIMITED REPAIR INSTALLED IN ACCORDANCE WITH REVISION 1 OF THIS SERVICE BULLETIN .................................................. 8 3 FIGURE 11: OPTION 2 PERMANENT REPAIR INSTALLATION FOR AIRPLANES WITH A TIME LIMITED REPAIR INSTALLED IN ACCORDANCE WITH REVISION 1 OF THIS SERVICE BULLETIN .................................................. 8 9 FIGURE 12: POST REPAIR EXTERNAL LFEC INSPECTION OF OPTION 1 PERMANENT REPAIR . 95 FIGURE 13: POST REPAIR EXTERNAL LFEC INSPECTION OF OPTION 2 PERMANENT REPAIR . 97 APPENDIX A: SKIN PANEL INSTALLATION DRAWINGS .......................... 9 9 APPENDIX B: PART DEMAND INTENT ................................... 1 0 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 737-53-1315Original Issue: July 29, 2011 Revision 1: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Skin - Station 727 to 1016 - Aft Skin Inspection, Repair and Replacement This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-16-07 is related to this service bulletin.

The effective date of AD 2012-16-07 is September 18, 2012.

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.

Effects of this Revision on airplanes on which Original Issue was previously done:

ActionConditionGroup Replace the skin panels in accordance with Revision 1 of this service bulletin.

All Airplanes.Group 1-6 Do the inspections in accordance with Revision 1 of this service bulletin.

Airplanes that have accomplished at least one inspection in accordance with the Original Issue of this service bulletin.

Continue post repair inspections and make the time limited repair permanent in accordance with Revision 1 of this service bulletin. Do post repair inspections of the permanent repair in accordance with Revision 1 of this service bulletin. (a) Airplanes that have accomplished the time limited repair in accordance with the Original Issue of this service bulletin.

No more work is necessary until the mandatory skin panel replacement in accordance with Revision 1 of this service bulletin.

Airplanes that have accomplished the permanent repair or made the time limited repair permanent in accordance with the Original Issue of this service bulletin. (a) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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ActionConditionGroup

(a) The definition of "permanent repair" has changed from the Original Issue to Revision 1 of this service bulletin. The term "permanent repair" in SB 737-53-1315, Original Issue, refers to the 737-500 SRM 53- 00-01, Figure 201, Repair 31, however in SB 737-53-1315, Revision 1, "permanent repair" refers to modifying the time limited repair in accordance with PART 5: PERMANENT REPAIR INSTALLATION.

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, and change airplane grouping.

The inspection areas have changed from three zones to two zones. In the Original Issue, Zones 1, 2, and 3 consisted of inspection areas of the skin where the bonded doublers are fully chem-milled to the bond line. The new zones include all previously inspected areas from the Original Issue of this service bulletin and additional areas where cracks could be found. Due to the change in zone definition, inspection criteria have been changed to enable early detection of cracks.

In order to mitigate Widespread Fatigue Damage (WFD) concerns, compliance and inspection requirements have changed as shown in the following two tables.

Original Issue Compliance Summary Threshold / Repeat IntervalsInspection Zone 22,000 / 4,500 flight cycles (external or internal inspections)Zone 1 (a) 22,000 / 4,500 flight cycles (external or internal inspections)Zone 2 (b) 22,000 / 3,700 flight cycles (external inspections)Zone 3 (c)

(a) Zone 1: Areas under the fairing which may or may not have had a history of cracks.

(b) Zone 2: Areas outside of the fairing that have similar loading and structural configuration as Zone 1 and Zone 3, but no history of cracks.

Revision 1 Compliance Summary Threshold / Repeat IntervalsInspection Zone 22,000 / 3,700 flight cycles (external or internal inspections)Zone 1 (a) 34,000 / 7,500 flight cycles (external inspections)Zone 2 (b)

(a) Zone 1: Skin and bonded doubler with the bonded doubler chem-milled to the bond line in the pocket.

(b) Zone 2: Skin and bonded doubler with a chem-milled pocket thickness of 0.050 inch and with the bonded doubler partially chem-milled.

Airplane grouping has been changed as follows:

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Airplane Grouping Changes Revision 1 GroupOriginal Issue Group 11 2 3 4 52 6 These sections were changed:

1. In Summary - Background, updated information and added planning data table.

2. In Summary - Action, updated information.

3. In Summary - Compliance, added AD statement(s).

4. In Summary - Effectivity, added line number range.

5. In Summary, revised the illustration.

6. In Paragraph 1.C., Reason, updated information.

7. In Paragraph 1.D., Description, updated information.

8. In Paragraph 1.E., Compliance, updated compliance table information and added AD statement(s).

9. In Paragraph 1.F., Approval, added AMOC statement.

10. In Paragraph 1.G., Manpower, included new tables for skin inspections, repairs and skin panel replacement.

11. In Paragraph 1.H., Weight and Balance Changes, added new tables.

12. In Paragraph 1.J., References, updated list of references, added list of drawings supplied with this service bulletin and added drawings used in the preparation of this service bulletin.

13. Added Paragraph 1.M., Software Accomplishment Summary.

14. In Paragraph 2.A., Material - Price and Availability, updated information.

15. In Paragraph 2.C., Parts Necessary for Each Airplane, updated information and added new replacement skin panel assembly parts.

16. In Paragraph 3.B., Work Instructions, updated instructions for inspections, repairs and skin panel replacement.

17. Figure 1 thru Figure 4, changed to show new and additional inspection requirements, revised applicability.

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18. Figure 5 and Figure 6, updated information and inspection methods.

19. Figure 7, revised the figure.

20. Added Figure 8 thru Figure 13.

21. Added Appendix A: Skin Panel Installation Drawings.

22. Added Appendix B: Part Demand Intent.

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 July 29, 2011Original Issue:

June 30, 2015Revision 1:

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Commercial Airplanes 737 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 737-53-1315Original Issue: July 29, 2011 Revision 1: June 30, 2015 ATA System: 5360 SUBJECT: FUSELAGE - Skin - Station 727 to 1016 - Aft Skin Inspection, Repair and Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS None.

BACKGROUND More than three hundred incidents of skin chem-mill cracks on twenty six airplanes have been reported from Body Station (STA) 727 to 1016 and Stringer S-14 to S-25 (left and right side) between 29,808 and 53,454 flight cycles. Most of the skin cracks were found aft of the wing at STA 747 and below the window belt on the left side.

Several of the reported cracks occurred in multiple adjacent bays. Since the release of the original version of this service bulletin, Boeing have completed a WFD assessment and chem-mill step cracks have been discovered while accomplishing general visual or detailed inspections in accordance with the Original Issue of this service bulletin. On the existing skin panel assembly, the doubler is chem-milled to the skin to create pockets of various depths. At these skin panel locations on the airplane, the loads could cause a condition where skin cracks could form along the longitudinal edges of the doubler. The many small cracks or Multiple Site Damage (MSD) in adjoining and identically stressed features can link together over many pressure cycles yielding a visible crack.

These cracks can merge together into a larger crack and compromise structural integrity of the airframe. Continued operation with undetected skin cracks could adversely affect the structural integrity of the airplane.

This service bulletin gives instructions for inspection, repair and information on replacement of skin panels where cracks 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 bulletin will allow early detection of cracks in the skin panels. The repair of skin cracks in accordance with this service bulletin will restore structural integrity of the skin panel. Replacement of the skin panels in accordance with this service bulletin is terminating action to the repeat inspections given in this service bulletin at the locations where the skin panels were replaced using production skin panels on airplanes with more than 53,000 total flight cycles.

Section 46 Lower Lobe skin panels have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).

Boeing Service Related Problems (SRP) 737-SRP-53-0416 and 737-SRP-53-0324 are related to this service bulletin.

Boeing Fleet Team Digest (FTD) 737 FTD 53-14003 is related to this service bulletin.

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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 AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/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 Do an external or internal inspection in Zone 1 and a detailed inspection in Zone 2 for any crack from STA 727 to STA 1016 and Stringer S-14 to Stringer S-25 on the left and right side of the airplane. If any crack is found, do either the time limited repair or the SRM repair in accordance with this service bulletin. If time limited repair is being accomplished, do the post time limited repair inspections until the time limited repair is made permanent in accordance with this service bulletin at times specified in Paragraph 1.E., Compliance. If the SRM repair is being accomplished, do the internal inspections in accordance with this service bulletin before accomplishing the SRM repair. Post repair inspections of the SRM repair must be accomplished in accordance with the SRM.

If no crack is found, repeat the inspections in accordance with this service bulletin.

If a time limited repair was accomplished in accordance with the Original Issue of this service bulletin, it must be made permanent in accordance with Revision 1 of this service bulletin at times specified in Paragraph 1.E., Compliance.

Replace the skin panels at the locations given below in accordance with this service bulletin.

Group 1-4:

– STA 727 to STA 908, S-14L to S-20L – STA 727 to STA 908, S-20L to S-25L – STA 908 to STA 1016, S-14L to S-20L – STA 908 to STA 1016, 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-20R to S-25R Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Group 5-6:

– STA 908 to STA 1016, 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 NOTE: The effectivity is divided into 6 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 inch.

EFFECTIVITY 737-500 airplanes, line numbers 1718-2494 and 2498-2553. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-16-07 is related to this service bulletin.

The effective date of AD 2012-16-07 is September 18, 2012.

Refer to Paragraph 1.E., Compliance.

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

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

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BOEING SERVICE BULLETIN 737-53-1315 STA

INSPECTION, 1016 REPAIR AND SKIN

PANEL REPLACEMENT FRAME & STRINGER & STRINGER

INSPECT SKIN FOR CRACKS REPAIR IF ANY CRACK IS FOUND. OUTBOARD VIEW OF SKIN (TYPICAL) 2367911

RIGHT SIDE SHOWN, LEFT SIDE SIMILAR Original Issue: July 29, 2011 Revision 1: June 30, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 737-53-1315 12 of 102

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