AIRWORTHINESS
DIRECTIVE
CAA-AD-060/2002
Date of issue: June 06, 2002
AIRCRAFT - AFT PRESSURE BULKHEAD - INSPECTION
Applicability: Model 737-100,
-200, -200C, -300, -400, and -500 series airplanes; line numbers (L/N) 1
through 3132 inclusive; certificated in any category.
Effective date: July 11, 2002
Compliance: Required as indicated in FAA AD 2002-10-11.
Remarks: The compliance of this AD must be recorded
in Aircraft Logbook, where applicable the requirements of this AD must be
integrated into Aircraft Technical Documentation. Address inquiries concerning
this AD to: Civil Aviation Authority, Airworthiness Division, Ruzyne Airport,
160 08 Prague 6, Czech Republic, tel.: 420 2 33320922, fax: 420 2 20562270.
Ing. Pavel MATOUŠEK
Director of Airworthiness Division
CAA CZ
2002-10-11 Boeing: Amendment 39-12757. Docket 2000-NM-359-AD.
Supersedes AD 84-20-03 R1, Amendment 39-5183.
Applicability: Model 737-100, -200, -200C, -300, -400, and -500 series
airplanes; line numbers (L/N) 1 through 3132 inclusive; certificated in any
category.
Note 1: This AD applies to each airplane identified in the preceding
applicability provision, regardless of whether it has been modified, altered,
or repaired in the area subject to the requirements of this AD. For airplanes
that have been modified, altered, or repaired so that the performance of the
requirements of this AD is affected, the owner/operator must request approval
for an alternative method of compliance in accordance with paragraph (h)(1) of
this AD. The request should include an assessment of the effect of the
modification, alteration, or repair on the unsafe condition addressed by this
AD; and, if the unsafe condition has not been eliminated, the request should
include specific proposed actions to address it.
Compliance: Required as indicated, unless accomplished previously.
To detect and correct corrosion or cracking of the aft pressure bulkhead at
Body Station (BS) 1016, which could result in loss of the aft pressure bulkhead
web and stiffeners and consequent rapid decompression of the fuselage,
accomplish the following:
Restatement of Requirements of AD 84-20-03 R1
Initial Inspection
(a) For Model 737 series airplanes with L/N 1 through 929 inclusive, with more
than 20,000 hours time-in-service or 7 years since date of manufacture, whichever
occurs first: Within 120 days after January 20, 1986 (the effective date of AD
84-20-03 R1, amendment 39-5183), unless already accomplished within the 21
months before January 20, 1986, visually inspect the BS 1016 pressure bulkhead
for cracking and corrosion; according to Boeing Alert Service Bulletin
737-53A1075, Revision 1, dated September 2, 1983; Revision 2, dated July 13,
1984; or Revision 3, dated June 8, 2000. Remove any obstruction to the drain
hole in the frame chord and replace any deteriorated leveling compound as noted
in the service bulletin. Treat the area of inspection with corrosion inhibitor
BMS 3-23, or equivalent.
Drain Hole Enlargement
(b) For airplanes identified in paragraph (a) of this AD: Within 1 year after
January 20, 1986, accomplish the drain hole enlargement as shown in Boeing
Alert Service Bulletin 737-53A1075, Revision 1, dated September 2, 1983;
Revision 2, dated July 13, 1984; or Revision 3, dated June 8, 2000.
Corrective Action
(c) If cracking or corrosion is found during any inspection required by
paragraph (a) or (d) of this AD, before further flight, repair according to
paragraph (c)(1) or (c)(2) of this AD.
(1) According to Boeing Alert Service Bulletin 737-53A1075, Revision 1, dated
September 2, 1983; Revision 2, dated July 13, 1984; or Revision 3, dated June
8, 2000.
(2) According to a method approved by the Manager, Seattle Aircraft
Certification Office (ACO), FAA; or per data meeting the type certification
basis of the airplane approved by a Boeing Company Designated Engineering
Representative (DER) who has been authorized by the Manager, Seattle ACO, to
make such findings. For a repair method to be approved by the Manager, Seattle
ACO, as required by this paragraph, the Manager's approval letter must
specifically reference this AD.
Repetitive Inspections
(d) For airplanes identified in paragraph (a) of this AD: Repeat the visual
inspections and corrosion inhibitor treatment in paragraph (a) at intervals not
to exceed 2 years, until paragraph (e) of this AD has been done.
New Requirements of This AD
Initial Inspection
(e) Do a detailed inspection for cracking or corrosion of the aft pressure
bulkhead at BS 1016 (including the forward and aft sides of the pressure web,
forward and aft sides of the pressure chord, pressure chord radius, forward and
aft sides of the angle stiffener, forward and aft chord, stringer end fitting,
system penetration doublers, channel stiffeners and fasteners, "Z"
stiffeners and fasteners, and fasteners common to the pressure chord and
pressure web), according to Boeing Alert Service Bulletin 737-53A1075, Revision
3, dated June 8, 2000. Do this inspection at the applicable time shown in
paragraph (e)(1), (e)(2), or (e)(3) of this AD.
Note 2: For the purposes of this AD, a detailed inspection is defined
as: "An intensive visual examination of a specific structural area,
system, installation, or assembly to detect damage, failure, or irregularity.
Available lighting is normally supplemented with a direct source of good
lighting at intensity deemed appropriate by the inspector. Inspection aids such
as mirror, magnifying lenses, etc., may be used. Surface cleaning and elaborate
access procedures may be required."
(1) For airplanes on which an inspection has previously been done according to
the requirements of paragraph (a) of this AD: Do the inspection within 2 years
since the most recent inspection according to paragraph (a) or (d) of this AD,
as applicable. Inspection according to paragraph (e) of this AD ends the requirement
for inspections according to paragraph (d) of this AD.
(2) For airplanes having L/N 930 through 1042 inclusive, on which an inspection
has not previously been done according to paragraph (a) of this AD: Do the
inspection within 2 years after the effective date of this AD.
(3) For airplanes having L/N 1043 through 3132 inclusive, on which an
inspection has not previously been done according to paragraph (a) of this AD:
Do the inspection within 6 years since the airplane's date of manufacture, or
within 2 years after the effective date of this AD, whichever occurs later.
Repetitive Inspections
(f) Repeat the inspection in paragraph (e) of this AD at the applicable time
shown in paragraph (f)(1) or (f)(2) of this AD.
(1) For airplanes having L/N 1 through 1042 inclusive: Repeat the inspection at
least every 2 years.
(2) For airplanes having L/N 1043 through 3132 inclusive: Repeat the inspection
at least every 4 years.
Repair
(g) If any corrosion or cracking is found during any inspection according to
paragraph (e) or (f) of this AD: Before further flight, repair according to
Boeing Alert Service Bulletin 737-53A1075, Revision 3, dated June 8, 2000.
Exception: If corrosion or cracking of the web and stiffeners is outside the
limits specified in the service bulletin, or if corrosion or cracking is found
in any structure not covered by the repair instructions in the service
bulletin, before further flight, repair according to a method approved by the
Manager, Seattle ACO, or per data meeting the type certification basis of the
airplane approved by a Boeing Company DER who has been authorized by the
Manager, Seattle ACO, to make such findings. For a repair method to be approved
by the Manager, Seattle ACO, as required by this paragraph, the Manager's
approval letter must specifically reference this AD.
Alternative Methods of Compliance
(h)(1) An alternative method of compliance or adjustment of the compliance time
that provides an acceptable level of safety may be used if approved by the Manager,
Seattle ACO. Operators shall submit their requests through an appropriate FAA
Principal Maintenance Inspector, who may add comments and then send it to the
Manager, Seattle ACO.
(2) Alternative methods of compliance, approved previously in accordance with
AD 84-20-03 R1, amendment 39-5183, are approved as alternative methods of
compliance with this AD.
Note 3: Information concerning the existence of approved alternative
methods of compliance with this AD, if any, may be obtained from the Seattle ACO.
Special Flight Permits
(i) Special flight permits may be issued in accordance with §§ 21.197 and
21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to
operate the airplane to a location where the requirements of this AD can be accomplished.
Incorporation by Reference
(j) Except as provided by paragraphs (c)(2) and (g) of this AD, the actions
shall be done in accordance with Boeing Alert Service Bulletin 737-53A1075,
Revision 1, dated September 2, 1983; Boeing Alert Service Bulletin 737-53A1075,
Revision 2, dated July 13, 1984; or Boeing Alert Service Bulletin 737-53A1075,
Revision 3, dated June 8, 2000, as applicable. This incorporation by reference
was approved by the Director of the Federal Register in accordance with 5 U.S.C.
552(a) and 1 CFR part 51. Copies may be obtained from Boeing Commercial
Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be
inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW.,
Renton, Washington; or at the Office of the Federal Register, 800 North Capitol
Street, NW., suite 700, Washington, DC.
Effective Date
(k) This amendment becomes effective on June 27, 2002.