SA-M 111

REV: 29 MAY 09 SOUTHWEST AIRLINES

DCA: 7748
AIRCRAFT CHANGE ORDER
A/C NO: 651

ACO #:

DATE:
7810-53

07/18/06
AD DATE:
FLEET: 737-300/-500

4 DIGIT ATA: 53-10

REV: 3 PAGE 1 OF 6
REV. DATE: 09/29/11

XXXX

COPY TO: N/A

TITLE: FUSELAGE - FORWARD CARGO DOOR CUTOUT, FORWARD FRAME (BS 440) REPLACEMENT

REQUESTED BY: PREPARED BY: REVIEWED BY: (SIGNATURE ON FILE)

ROSE ARCENEAUX
214/792-2790
ENGINEERING REVISED BY: ROSE ARCENEAUX APPROVED BY: (SIGNATURE ON FILE)

214/792-2790 (SIGNATURE ON FILE)

REVISION TO ACO
(NOT APPLICABLE IF SHADED)

AIRCRAFT MODIFIED PER PREVIOUS RELEASES OF THIS ACO REQUIRE ADDITIONAL WORK OR REWORK: [ ] YES
[ X ] NO

EFFECTIVITY CHANGE: [ ] YES

[ X ] NO

DESCRIPTION OF CURRENT REVISION: REVISED AIRWORTHINESS DIRECTIVE, APPROVED DATA, REFERENCE DATA,
GROUP LISTING .I.D., CLASSIFICATION, HOURS/CYCLES/DAYS/DIE DATE (DIE
DATE = REGULATORY MANDATES ONLY), PLANNING INFORMATION AND WORK
ACCOMPLISHMENT INSTRUCTIONS.
REV DATE PREVIOUS REVISION HISTORY

2 11/27/06 REVISED WORK ACCOMPLISHMENT INSTRUCTIONS.

REGULATORY MOD
(not applicable if shaded)

AIRWORTHINESS DIRECTIVE: AD 2005-07-19, AMENDMENT 39-14044

(NUMBER & TITLE)

DESCRIPTION: REPLACEMENT OF FORWARD CARGO DOOR CUTOUT, FORWARD FRAME (BS

440) WITH PRODUCTION EQUIVALENT.
REASON: NUMEROUS CRACKS HAVE BEEN REPORTED IN THE SKIN, BONDED DOUBLER
BEARSTRAP AND FRAMES OF THE FORWARD AND AFT CARGO DOOR CUTOUT.
APPROVED DATA: SB 737-53A1228, DATED 10 JUL 2003

REFERENCE DATA: SI 11480-53 REV 4

EFFECTIVITY: 737-300 SERIES, LINE NUMBERS 1037-2932

737-500 SERIES, LINE NUMBERS 1718-2292

RII
ACCOMPLISHED:___________________________________ ACCOMPLISHED:________________________________
AMT DATE INSPECTOR DATE
SA-M 111
SOUTHWEST AIRLINES A/C NO: 651
REV: 29 MAY 09
DCA: 7748
AIRCRAFT CHANGE ORDER DATE:

ACO #: 7810-53 FLEET: 737-300/-500

REV #: 3
REV DATE: 09/29/11
AD 4 DIGIT ATA: 53-10
PAGE 2 OF 6

EXCEPTIONS: N/A

GROUP LISTING I.D.: ATTACHED [ X ] NOT AFFECTED [ ]

A/C MODEL: 737-300/-500 CLASSIFICATION

ATA SYSTEM: 53-10 [ X ] MINOR [ X ]REPAIR

MAJOR COMPONENT: FUSELAGE [ ] MAJOR [ ] ALTERATION

PUB. CHANGE REQ.: N/A WEIGHT & BALANCE

WARRANTY: N/A DATA ATTACHED: [ ] NOT AFFECTED: [X]

LABOR HOURS: 84.0

DOWNTIME HOURS: 84.0

APPLICABLE TO NEW N/A

DELIVERY AIRCRAFT:
APPLICABLE TO FUTURE YES
LEASED AIRCRAFT:
SPECIAL REQUIREMENTS: N/A

SWA MPD25 AFFECTED: N/A

ACO TERMINATES: N/A

RECOMMENDED LOWEST MOD

LEVEL CHECK TYPE
COORDINATED WITH MX
OPS:
LIMIT SPECIFICATIONS: HOURS/CYCLES/DAYS/DIE DATE (DIE DATE = REGULATORY MANDATES ONLY)
[ ] REGULATORY MANDATE
[ X ] SWA MANDATE ACCOMPLISH ON CONDITION AS DETERMINED BY RESULTS OF INSPECTION PER
[ ] SWA RECOMMENDED SI 11480-53.

NOTE TO RECORDS:
AFTER ACCOMPLISHMENT OF THIS ACO, ASSIGNMENT FOR SI 11480-53 TO BE
RESET TO 20,000 FLIGHT CYCLES FROM DATE OF ACCOMPLISHMENT OF THIS
ACO.
 SA-M 111
SOUTHWEST AIRLINES A/C NO: 651
REV: 29 MAY 09
DCA: 7748
AIRCRAFT CHANGE ORDER DATE:

ACO #: 7810-53 FLEET: 737-300/-500

REV #: 3
REV DATE: 09/29/11
AD 4 DIGIT ATA: 53-10
PAGE 3 OF 6

TITLE: FUSELAGE - FORWARD CARGO DOOR CUTOUT, FORWARD FRAME (BS 440) REPLACEMENT

1. PLANNING INFORMATION

A. DESCRIPTION

Replacement of Forward Cargo Door Cutout, Forward Frame (BS 440) with production equivalent.

B. REASON

Numerous cracks have been reported in the skin, bonded doubler, bearstrap and frames of the forward and aft cargo
door cutouts.

C. EFFECTIVITY

737-300 Series Line Numbers 1037-2932

737-500 Series Line Numbers 1718-2292

D. WEIGHT & BALANCE

N/A

E. REFERENCES

737-300/-500 SRM 51-20-01, 51-20-05, and 51-30-03

F. PUBLICATIONS AFFECTED

(1) Maintenance

N/A

(2) Flight Operations

N/A
 SA-M 111
SOUTHWEST AIRLINES A/C NO: 651
REV: 29 MAY 09
DCA: 7748
AIRCRAFT CHANGE ORDER DATE:

ACO #: 7810-53 FLEET: 737-300/-500

REV #: 3
REV DATE: 09/29/11
AD 4 DIGIT ATA: 53-10
PAGE 4 OF 6

2. MATERIAL INFORMATION

A. PARTS NECESSARY FOR EACH AIRPLANE

SI/N MPN DESCRIPTION QTY UI %

1530303 65-20722-70 FRAME, BS 440 1 EA 100
(AIRCRAFT 300-351, 657-699, 501-507)
3953003 65-20722-76 FRAME, BS 440 1 EA 100
(AIRCRAFT 352-356, 508-524)
3953004 65-20722-98 FRAME, BS 440 1 EA 100
(AIRCRAFT 357-399,525-528, 600-656)

B. PARTS NECESSARY TO CHANGE SPARES

N/A

C. SPECIAL TOOLS/EQUIPMENT REQUIRED

SI/N MPN DESCRIPTION QTY

N/A N/A N/A N/A

D. EXISTING PARTS ACCOUNTABILITY

Discard removed frames.

SA-M 111
SOUTHWEST AIRLINES A/C NO: 651
REV: 29 MAY 09
DCA: 7748
AIRCRAFT CHANGE ORDER DATE:

ACO #: 7810-53 FLEET: 737-300/-500

REV #: 3
REV DATE: 09/29/11
AD 4 DIGIT ATA: 53-10
PAGE 5 OF 6

WORK ACCOMPLISHMENT INSTRUCTIONS AMT INSP DATE

GENERAL NOTES:
1. Detailed Visual Inspection is defined as follows:
- An intensive examination of a specific item, installation or
assembly to detect damage, failure or irregularity.
- Available lighting is normally supplemented with a direct
source of good lighting at an intensity deemed appropriate.
- Inspection aids such as mirrors, magnifying lenses, etc.,
may be necessary.
2. BS440 and BS492 as referenced in this document are for
737-300 series aircraft. For 737-500 series aircraft, substitute
BS400 for BS440, and BS452 for BS492.
1. Frame Replacement at BS 440
A. Gain access to facilitate replacement of the frame
Generate non-routine cards to document access requirements
for frame replacement and list below:
_______________________________________________
_______________________________________________
_______________________________________________
B. Remove and discard existing frame at BS 440.

C. Perform a detailed visual inspection of the frame support

structure at BS 440, stringers 16R to 28R for signs of corrosion,
cracks or other damage. Generate a non-routine card for any
damage found.
Record NRC:
_______________________________________
_______________________________________
_______________________________________
SA-M 111
SOUTHWEST AIRLINES A/C NO: 651
REV: 29 MAY 09
DCA: 7748
AIRCRAFT CHANGE ORDER DATE:

ACO #: 7810-53 FLEET: 737-300/-500

REV #: 3
REV DATE: 09/29/11
AD 4 DIGIT ATA: 53-10
PAGE 6 OF 6

WORK ACCOMPLISHMENT INSTRUCTIONS AMT INSP DATE

CAUTION: IN SOME CASES, FRAMES AT BS 440 AND BS 492 RII
MAY REQUIRE REPLACMENT. FRAMES AT BS 440
AND BS 492 SHALL NOT BE REMOVED
CONCURRENTLY FROM AIRCRAFT. ONE OF THE
FRAMES BEING REPLACED MUST BE POSITIONED
AND SECURED IN PLACE WITH TEMPORARY
ATTACHMENTS (CLECOS OR EQUIVALENT) PRIOR
TO REMOVAL OF OTHER FRAME THAT IS BEING
REPLACED.
D. Install new frame using same type and size fasteners as
removed, oversized fasteners as required. Reference
737-300/-500 SRM 51-40-02, 51-40-05 and 51-20-01. Reference
frame installation drawing:
Installation Drawing Tail Numbers
65-20722-51 300-351, 657-699
65-20722-81 352-375
65-20722-87 376-399, 600-656
65C33514-1 501-507
65C33514-7 508-528

Frame Part Number Tail Numbers

65-20722-70 300-351, 657-699, 501-507
65-20722-76 352-356, 508-524
65-20722-98 357-399, 525-528, 600-656
2. Aircraft Restoration
A. Restore aircraft to normal configuration.