SB 737 55 1059 01

Commercial
Airplanes
737
Service Bulletin
SPECIAL ATTENTION
Number: 737-55-1059
Original Issue: September 10, 1998
Revision 1: April 06, 2016
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Inspection and Repair
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.
ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 1998 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Unpublished Work.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.

Revision 1: April 06, 2016 737-55-1059
1 of 85
3.0
BOEING SERVICE BULLETIN 737-55-1059
BLANK PAGE

Export Controlled ECCN: 9E991 - BOEING
Revision 1: April 06, 2016 PROPRIETARY - Copyright © Unpublished
737-55-1059
Work - See page 1 for details. 2 of 85
Table of Contents
Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 32
4. Process Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 36
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 37
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FIGURE 1: LEFT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION [Group 1,
Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FIGURE 2: RIGHT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION [Group 1,
Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FIGURE 3: STOP DRILL REPAIR [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . 56
FIGURE 4: EXTERNAL DOUBLER REPAIR INSTALLATION [Group 1, Configuration 1] . . . . . . . 57
FIGURE 5: HORIZONTAL STABILIZER LOWER SKIN SRM REPAIR OR EXTERNAL DOUBLER REPAIR
- POST-REPAIR INSPECTION [Group 1, Configuration 2] . . . . . . . . . . . . . . . . . 61
FIGURE 6: LEFT HORIZONTAL STABILIZER LOWER SKIN OF UNREPAIRED AREAS - POST-REPAIR
INSPECTION [Group 1, Configuration 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

737-55-1059
FIGURE 7: RIGHT HORIZONTAL STABILIZER LOWER SKIN OF UNREPAIRED AREAS - POST-REPAIR

INSPECTION [Group 1, Configuration 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FIGURE 8: FORWARD FASTENER ROW OF EXTERNAL DOUBLER REPAIR - LOW FREQUENCY EDDY
CURRENT INSPECTION [Group 1, Configuration 2] . . . . . . . . . . . . . . . . . . . . . 67
FIGURE 9: CUT OUT REPAIR [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . 70
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: LEFT AND RIGHT
HORIZONTAL STABILIZER LOWER SKINS THAT DO NOT HAVE A REPAIR INSTALLED –
INSPECTION AND REPAIR [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . 72
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: LEFT AND RIGHT
HORIZONTAL STABILIZER LOWER SKINS WITH AN EXISTING REPAIR INSTALLED -
POST-REPAIR INSPECTION AND REPAIR [Group 1, Configuration 2] . . . . . . . . . . 77
APPENDIX C: INBOARD SKIN SPLICE REPAIRS - JACKING AND SHORING . . . . . . . . . . . . . . 81
APPENDIX D: INBOARD SKIN SPLICE REPAIRS - JACKS AND SHORING SUPPORT - REMOVAL . . 82
APPENDIX E: OUTBOARD SKIN SPLICE REPAIRS - JACKING AND SHORING . . . . . . . . . . . . . 83
APPENDIX F: OUTBOARD SKIN SPLICE REPAIRS - JACKS AND SHORING SUPPORT - REMOVAL . 84
APPENDIX G: BOEING PART DEMAND INTENT [Group 1, Configuration 1] . . . . . . . . . . . . . . . . 85

737-55-1059
Commercial
Airplanes
737
Service Bulletin
SPECIAL ATTENTION
Number: 737-55-1059 Revision Transmittal Sheet
ATA System: 5510
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Airplane line numbers 3006 - 3132 were added to this service bulletin effectivity.
Effects of this Revision on airplanes on which the Original Issue was previously done:
Group Condition Action

Group 1, Configuration 1 Left and right horizontal stabilizer Do detailed inspections of the hori-
lower skins in Zone-A to Zone-F that zontal stabilizer lower skin for any
do not have a repair installed. crack.
Group 1, Configuration 2 Left and right horizontal stabilizer Do post-repair inspections of the
lower skins in Zone-A to Zone-F with horizontal stabilizer lower skin for
an existing repair, excluding Boeing any crack.
approved skin splice repairs.
REASON FOR REVISION
This revision is sent to introduce new repeat inspections for any crack in the horizontal stabilizer lower skin, an
updated external doubler repair, a new preventive modification, a new permanent skin splice repair and a new
Top Kit.
These sections were changed:
1. In Background, in the Summary section, added new information and a Summary Evaluation Table.
2. In Action, in the Summary section, changed instructions.
3. In Effectivity, in the Summary section, updated reference.
4. In Compliance, in the Summary section, removed information and added reference.
5. In Industry Support Information, in the Summary section, added warranty information.
6. In Manpower, in the Summary section, removed paragraph and added reference.

737-55-1059
7. In Material Information, in the Summary section, changed supplier information, added reference and
survey information.
8. In Summary illustration, in the Summary section, changed inspection area, added skin replacement
area and changed instructions.
9. In Paragraph 1.A., Effectivity, added line numbers 3006-3132 to Group 1, added note and divided the
effectivity into configurations.
10. In Paragraph 1.C., Reason, added new information and reason for this revision.
11. In Paragraph 1.D., Description, changed instructions and added maintenance zone table.
12. In Paragraph 1.E., Compliance, added new repeat inspection and corrective action information in tables.
13. In Paragraph 1.F., Approval, added approvals from European Aviation Safety Agency and Joint Aviation
Authorities.
14. In Paragraph 1.G., Manpower, updated information and added tables for new repairs, new preventive
modification, post-repair inspection and open hole inspection.
15. In Paragraph 1.H., Weight and Balance Changes, removed table for a doubler installation, added table
for new permanent skin splice repairs and preventive modification.
16. In Paragraph 1.J.1., References, updated existing data.
17. In Paragraph 1.J.2., Data Supplied with this Service Bulletin, added drawings supplied with this service
bulletin.
18. In Paragraph 1.K.1., Publications, added affected publication.
19. In Paragraph 1.K.2., Damage Tolerance Based Structural Inspections, added effects and reference.
20. In Paragraph 1.L., Interchangeability and Intermixability of Parts, added effect on parts.
21. In Paragraph 1.M., Software Accomplishment Summary, added effect.
22. In Paragraph 2.A., Material - Price and Availability, removed old Top Kits, added new Top Kit, revised
price.
23. In Paragraph 2.B., Industry Support Information, added warranty information.
24. In Paragraph 2.C., Parts Necessary for Each Airplane, updated the Kits/Parts table and the Parts and
Materials Supplied by the Operator table.
25. In Paragraph 3.A., General Information, revised the general notes in accordance with new requirements
and added terminating actions.
26. In Paragraph 3.B., Work Instructions, removed the permanent 0.063 inch doubler installation and repair,
added repairs, preventive modification, post-repair inspection and open hole inspection.
27. In Figure 1, inspections area extended and limited to left horizontal stabilizer lower skin only, additional
optional inspections added.

737-55-1059
28. Figure 2, added new figure for inspections.
29. Figure 3, separated repairs and moved to correct sequence.
30. Figure 4, changed fastener codes and added views.
31. In Figure 5, added post-repair inspection.
32. In Figure 6, added post-repair inspection of unrepaired bays on left horizontal stabilizer lower skin.
33. In Figure 7, added post-repair inspection of unrepaired bays on right horizontal stabilizer lower skin.
34. In Figure 8, added inspection of forward fastener row of external doubler repair.
35. In Figure 9, added repair as a separate figure.
36. Appendices A and B, added logic diagrams for compliance.
37. Appendix C, added jacking and shoring instructions for inboard skin splice repair.
38. Appendix D, added jacks and shoring support removal instructions for inboard skin splice repair.
39. Appendix E, added jacking and shoring instructions for outboard skin splice repair.
40. Appendix F, added jacks and shoring support removal instructions for outboard skin splice repair.
41. Appendix G, added Boeing Part Demand Intent.
The data given in Information Notice 737-55-1059 IN 01 and IN 02 is included in this revision.
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


737-55-1059
BLANK PAGE

737-55-1059
Commercial
Airplanes
737
Service Bulletin
SPECIAL ATTENTION
Number: 737-55-1059 Summary
ATA System: 5510
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Accomplishment of the work in this service bulletin will make sure that any crack found on the lower skins of the
horizontal stabilizer is detected and repaired. If the work given in this service bulletin is not accomplished, a
crack in the lower skin of the horizontal stabilizer may go undetected and grow in length. An undetected crack
and continuous operation of the airplane will cause reduced local stiffness of the stabilizer which can cause
heavy vibration leading to loss of structural integrity.
Nearly ninety cracks have been reported in horizontal stabilizer lower skins with most of them occurring between
Stabilizer Station (SSTA) 111.10 and 166.30. Ten operators reported cracks on eighteen airplanes outside this
range with fourteen of them inboard of SSTA 111.10. The cracks range in length from 0.25 inch to 3.75 inch
and the airplanes had between 12,670 and 69,569 flight cycles. The cracks started on the outer surface of the
skin where the chem-mill edge aligns with the edge of the lower flange of the rear spar. The cracks grew parallel
to the rear spar. High secondary bending stresses due to compression buckling of the skins and sonic fatigue
can cause the cracks to grow. Cracks also start from the fastener line nearest the chem-mill step. The cracks
were discovered during regular, scheduled maintenance inspections. Installation of new, non-chem milled skin
panels and an external doubler section have been used successfully over a number of years without reports of
additional cracking.
Boeing Structural Item Interim Advisory (SIIA) SIIA 737-250 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-55-0014 and 737-SRP-55-0039 are related to this service
bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 55-06003 is related to this service bulletin.

737-55-1059
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected
AD Related Yes Paragraph 1.E., Compliance and Paragraph
1.F., Approval
Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes
Electrical Load Changed No Paragraph 1.I., Electrical Load Data
Publications Affected No Paragraph 1.K., Publications Affected
Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts
Operator Supplied Parts/Material Yes Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
Special Tooling Required No Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
ACTION
Group 1, Configuration 1:
Do a detailed inspection of left and right side lower skins of the horizontal stabilizers between SSTA 83.50 and
SSTA 249.10 for any crack. If any crack is found between SSTA 83.50 and SSTA 180.00, do the skin splice
repair and end inspections or install a Structural Repair Manual (SRM) repair or an external repair doubler and
do post repair inspections. SRM repair installation is an option for any crack found between SSTA 83.50 and
SSTA 157.10. External repair doubler installation is an option for any crack found between SSTA 111.10 and
SSTA 166.30. If any crack is found between SSTA 180.00 and SSTA 249.10, contact The Boeing Company for
repair instructions and do the repair. If no crack is found, continue inspections until the skin splice repair is done
or do a preventive modification to end inspections between SSTA 83.50 and SSTA 101.90 only.
Do post repair inspections of left and right side lower skins of the horizontal stabilizers between SSTA 83.50
and SSTA 249.10 for any crack. If any crack is found between SSTA 83.50 and SSTA 180.00, do the skin splice
repair and end inspections. If any crack is found between SSTA 180.00 and SSTA 249.10, contact The Boeing
Company for repair instructions and do the repair. If no crack is found between SSTA 83.50 and SSTA 180.00,
continue post repair inspections until the skin splice repair is done. If no crack is found between SSTA 180.00
and SSTA 249.10, repeat post repair inspections.
EFFECTIVITY
All 737-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

737-55-1059
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 procedures given in this service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX G of this service bulletin to help Boeing
predict the quantity and timing of the Boeing Supplied Kits/Parts.

737-55-1059

737-55-1059
Commercial
Airplanes
737
Service Bulletin
SPECIAL ATTENTION
Number: 737-55-1059
ATA System: 5510
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
1. PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is applicable to 737-300/-400/-500 Airplanes, line numbers 1001-3132 in one
Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index Document D6-19567, Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
NOTE: Prior to the release date of SB 737-55-1059 Revision 1, if a Boeing ODA FAA Form
8100-9 approved skin splice repair was installed, and the splice and replaced segment
of skin is in the same location as the part 4, part 5, part 6, or part 7 skin splice repair
given in paragraph 3.B., Work Instructions of this service bulletin, then the corresponding
paragraph 3.A., General Information note regarding inspection termination applies.
GROUP CONFIGURATION DESCRIPTION
1 - 737-300/-400/-500 airplanes. Line number 1001 to 3132.
1 Left and right horizontal stabilizer lower skins in Zone-A to Zone-F

that do not have a repair installed.
2 Left and right horizontal stabilizer lower skins in Zone-A to Zone-F

with an existing repair, excluding Boeing approved skin splice repairs.
Airplane Models:
737-300, 737-400, 737-500

737-55-1059
Variable Number Group

PJ301 - PJ302 1
PJ551 - PJ561 1
PJ601 - PJ615 1
PJ811 1
PJ816 - PJ817 1
PM381 - PM399 1
PM401 - PM417 1
PM541 - PM564 1
PP001 - PP054 1
PP101 - PP169 1
PP181 - PP199 1
PP201 - PP205 1
PP221 1
PP231 - PP243 1
PP281 - PP286 1
PP301 - PP305 1
PP351 - PP353 1
PP376 - PP384 1
PP391 - PP393 1
PP401 - PP440 1
PP471 - PP475 1
PP501 - PP522 1
PP631 - PP634 1
PP651 - PP652 1
PP671 - PP699 1
PP701 - PP733 1
PP771 - PP779 1
PP801 - PP808 1
PP821 - PP827 1
PP831 - PP848 1
PP851 - PP852 1
PP861 - PP877 1

737-55-1059

PP891 - PP899 1
PP901 - PP936 1
PP946 - PP948 1
PP951 - PP952 1
PP961 - PP967 1
PP981 - PP991 1
PP993 1
PQ001 - PQ016 1
PQ026 - PQ041 1
PQ051 - PQ092 1
PQ101 - PQ199 1
PQ201 - PQ202 1
PQ221 - PQ237 1
PQ241 - PQ243 1
PQ251 - PQ267 1
PQ281 - PQ299 1
PQ301 - PQ307 1
PQ331 - PQ332 1
PQ341 - PQ348 1
PQ361 - PQ373 1
PQ391 - PQ395 1
PQ401 - PQ418 1
PQ421 1
PQ431 - PQ438 1
PQ447 - PQ448 1
PQ451 1
PQ454 1
PQ471 - PQ475 1
PQ479 - PQ481 1
PQ486 - PQ487 1
PQ491 - PQ493 1
PQ771 - PQ772 1
PQ791 - PQ793 1

737-55-1059

PQ801 - PQ805 1
PQ931 - PQ935 1
PQ951 1
PQ971 - PQ997 1
PR001 - PR017 1
PR021 - PR034 1
PR041 - PR045 1
PR061 - PR072 1
PR077 - PR082 1
PR091 - PR092 1
PR096 1
PR101 1
PR121 - PR122 1
PR131 - PR132 1
PR141 - PR143 1
PR161 - PR172 1
PR181 1
PS601 - PS631 1
PS636 - PS638 1
PS641 - PS644 1
PS651 - PS657 1
PS666 - PS669 1
PS691 - PS692 1
PS701 - PS706 1
PS751 - PS799 1
PS811 1
PS836 - PS837 1
PS841 - PS846 1
PS851 - PS852 1
PS856 1
PS861 - PS863 1
PS866 - PS868 1
PS871 - PS874 1

737-55-1059

PS896 - PS897 1
PS901 - PS941 1
PS956 - PS957 1
PS961 - PS963 1
PS971 - PS978 1
PT001 - PT015 1
PT021 - PT031 1
PT041 - PT064 1
PT101 - PT105 1
PT121 - PT138 1
PT146 - PT148 1
PT161 - PT170 1
PT181 - PT188 1
PT211 - PT220 1
PT295 1
PT301 - PT309 1
PT331 - PT360 1
PT381 - PT399 1
PT401 - PT438 1
PT501 - PT517 1
PT561 - PT565 1
PT581 - PT586 1
PT611 - PT621 1
PT641 - PT644 1
PT651 - PT656 1
PT671 - PT672 1
PT681 - PT685 1
PT701 - PT703 1
PT716 - PT717 1
PT721 - PT725 1
PT801 - PT834 1
PT851 - PT854 1
PT871 - PT886 1

737-55-1059

PT901 - PT930 1
PT971 - PT973 1
PT981 - PT985 1
PT996 1
PU001 - PU025 1
PU301 1
PU311 - PU313 1
PV001 - PV055 1
PV201 - PV209 1
PV226 - PV229 1
PV231 - PV237 1
PV271 - PV272 1
PV281 - PV287 1
PV296 1
PV301 - PV302 1
PV351 1
PV356 - PV357 1
PW001 - PW054 1
PW061 - PW068 1
PW072 1
PW086 - PW088 1
PW091 - PW094 1
PW101 - PW102 1
PW106 1
PW111 - PW120 1
PW156 - PW157 1
PW161 - PW171 1
PW201 - PW252 1
PW261 - PW268 1
PW271 - PW276 1
PW278 1
PW281 - PW293 1
PW296 1

737-55-1059

PW301 - PW327 1
PW401 - PW408 1
PW411 - PW418 1
PW421 - PW424 1
PW431 - PW435 1
PW441 - PW450 1
PW461 - PW467 1
PW501 - PW504 1
PW511 - PW522 1
PW524 - PW550 1
PW556 - PW557 1
PW561 - PW564 1
PW571 - PW576 1
PW591 - PW596 1
PW611 - PW622 1
PW631 - PW637 1
PW661 - PW662 1
PW681 - PW683 1
PW701 - PW702 1
PW711 - PW717 1
PW741 - PW742 1
PW761 1
PW771 1
PW831 1
PW851 - PW856 1
2. Spares Affected
None.
B. Concurrent Requirements
None.

737-55-1059
C. Reason
Accomplishment of the work in this service bulletin will make sure that any crack found on the lower
skins of the horizontal stabilizer is detected and repaired. If the work given in this service bulletin is not
accomplished, a crack in the lower skin of the horizontal stabilizer may go undetected and grow in
length. An undetected crack and continuous operation of the airplane will cause reduced local stiffness
of the stabilizer which can cause heavy vibration leading to loss of structural integrity.
Nearly ninety cracks have been reported in horizontal stabilizer lower skins with most of them occurring
between Stabilizer Station (SSTA) 111.10 and 166.30. Ten operators reported cracks on eighteen
airplanes outside this range with fourteen of them inboard of SSTA 111.10. The cracks range in length
from 0.25 inch to 3.75 inch and the airplanes had between 12,670 and 69,569 flight cycles. The cracks
started on the outer surface of the skin where the chem-mill edge aligns with the edge of the lower
flange of the rear spar. The cracks grew parallel to the rear spar. High secondary bending stresses
due to compression buckling of the skins and sonic fatigue can cause the cracks to grow. Cracks also
start from the fastener line nearest the chem-mill step. The cracks were discovered during regular,
scheduled maintenance inspections. Installation of new, non-chem milled skin panels and an external
doubler section have been used successfully over a number of years without reports of additional
cracking.
Boeing Structural Item Interim Advisory (SIIA) SIIA 737-250 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-55-0014 and 737-SRP-55-0039 are related to this
service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 55-06003 is related to this service bulletin.
This revision is sent to introduce new repeat inspections for any crack in the horizontal stabilizer lower
skin, an updated external doubler repair, a new preventive modification, a new permanent skin splice
repair and a new Top Kit.
D. Description
Do a detailed inspection of left and right side lower skins of the horizontal stabilizers between SSTA
83.50 and SSTA 249.10 for any crack. If any crack is found between SSTA 83.50 and SSTA 180.00,
do the skin splice repair and end inspections or install a Structural Repair Manual (SRM) repair or an
external repair doubler and do post repair inspections. SRM repair installation is an option for any crack
found between SSTA 83.50 and SSTA 157.10. External repair doubler installation is an option for any
crack found between SSTA 111.10 and SSTA 166.30. If any crack is found between SSTA 180.00 and
SSTA 249.10, contact The Boeing Company for repair instructions and do the repair. If no crack is
found, continue inspections until the skin splice repair is done or do a preventive modification to end
inspections between SSTA 83.50 and SSTA 101.90 only.
Do post repair inspections of left and right side lower skins of the horizontal stabilizers between SSTA
83.50 and SSTA 249.10 for any crack. If any crack is found between SSTA 83.50 and SSTA 180.00,
do the skin splice repair and end inspections. If any crack is found between SSTA 180.00 and SSTA
249.10, contact The Boeing Company for repair instructions and do the repair. If no crack is found
between SSTA 83.50 and SSTA 180.00, continue post repair inspections until the skin splice repair is
done. If no crack is found between SSTA 180.00 and SSTA 249.10, repeat post repair inspections.
Effects of this Revision on airplanes on which the Original Issue was previously done:

737-55-1059
Group Condition Action

Group 1, Configuration 1 Left and right horizontal stabilizer Do detailed inspections of the hori-
lower skins in Zone-A to Zone-F that zontal stabilizer lower skin for any
do not have a repair installed. crack.
Group 1, Configuration 2 Left and right horizontal stabilizer Do post-repair inspections of the
lower skins in Zone-A to Zone-F with horizontal stabilizer lower skin for
an existing repair, excluding Boeing any crack.
approved skin splice repairs.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones

Model Zone
737-300, 737-400, 737-500 709, 710
E. 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.
Logic diagrams showing compliance tasks and compliance times are included as an aid in APPENDIX
A and APPENDIX B.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When
more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION
numbers for that CONDITION number or OPTION number.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
NOTE: Prior to the release date of SB 737-55-1059 Revision 1, if a Boeing ODA FAA Form 8100-9
approved skin splice repair was installed, and the splice and replaced segment of skin is in
the same location as the part 4, part 5, part 6, or part 7 skin splice repair given in paragraph
3.B., Work Instructions of this service bulletin, then the corresponding paragraph 3.A., General
Information note regarding inspection termination applies.

737-55-1059
Table 1: Left and Right Horizontal Stabilizer Lower Skins That Do Not Have a Repair Installed - Inspection
and Repair
Condition Action Compliance Time (Whichever Repeat Interval

Occurs Later) (Not to Exceed)
All left and right horizontal Do PART 1: DETAILED Before 15,000 Within 7,000 -
stabilizer lower skins that INSPECTION OF THE total horizontal horizontal stabi-
do not have a repair in- HORIZONTAL STABILIZ- stabilizer flight lizer flight cycles
stalled in Zone-A to Zone- ER LOWER SKIN for any cycles. after the Revi-
F. crack. sion 1 date of
this service bul-
letin.
CONDITION 1: Repeat PART 1: DE- - 4,500 flight cycles.
NO CRACK FOUND IN TAILED INSPECTION
ZONE-A or ZONE-B or OF THE HORIZONTAL
ZONE-C or ZONE-D or STABILIZER LOWER
ZONE-E or ZONE-F. SKIN for any crack. (a)
(b) (c) (d) (e)
CONDITION 2: ANY OPTION 1: Do PART 4: Before further flight. -
CRACK FOUND IN ZONE- SKIN SPLICE REPAIR IN
A. ZONE-A. (a)
OPTION 2: Do an exter- Before further flight. -
nal doubler repair in ac-
cordance with the SRM.
(f) (g)
B. ZONE-B. (b)
(f) (g)
C. ZONE-C. (c)
(f) (g) (h)
OPTION 3: Do PART 8: Before further flight. -
EXTERNAL DOUBLER
REPAIR. (f) (i)

737-55-1059
Table 1: Left and Right Horizontal Stabilizer Lower Skins That Do Not Have a Repair Installed - Inspection
and Repair

D. ZONE-D. (d)
(f) (g) (h)
OPTION 3: Do PART 8: Before further flight. -
EXTERNAL DOUBLER
REPAIR. (f) (i)
CONDITION 6: ANY Contact The Boeing Before further flight. -
CRACK FOUND IN ZONE- Company for repair in-
E or ZONE-F. structions and do the re-
pair.
(a) Accomplishment of PART 4: SKIN SPLICE REPAIR IN ZONE-A is terminating action to the inspections
between SSTA 83.50 and SSTA 111.10.
(b) Accomplishment of PART 5: SKIN SPLICE REPAIR IN ZONE-B is terminating action to the inspections
(c) Accomplishment of PART 6: SKIN SPLICE REPAIR IN ZONE-C is terminating action to the inspections
(d) Accomplishment of PART 7: SKIN SPLICE REPAIR IN ZONE-D is terminating action to the inspections
(e) Accomplishment of PART 2: PREVENTIVE MODIFICATION IN ZONE-A or PART 3: PREVENTIVE
MODIFICATION IN ZONE-B is terminating action to the inspections between SSTA 83.50 and SSTA
101.90.
(f) Refer to Table 2 for compliance information related to post-repair inspections of SRM doubler repairs or
external doubler repairs.
(g) Do the repair in accordance with 737-300 SRM 55-10-01, Repair 13 or 737-400 SRM 55-10-01, Repair
13 or 737-500 SRM 55-10-01, Repair 13.
(h) This option only applies for any crack found in ZONE-C or ZONE-D between SSTA 105.70 and SSTA
157.10.
(i) This option only applies for any crack found in ZONE-C or ZONE-D between SSTA 111.10 and SSTA
166.30.

737-55-1059
Table 2: Left and Right Horizontal Stabilizer Lower Skins With An Existing Repair Installed - Post-Repair
Inspection and Repair

All left and right horizontal Do PART 9: POST-RE- Within 12 Within 12 -
stabilizer lower skins with PAIR INSPECTION OF months after in- months after the
an existing repair installed. THE HORIZONTAL STA- stallation of the Revision 1 date
(a) BILIZER LOWER SKIN repair. of this service
for any crack and for any bulletin.
loose or any missing fas-
tener. (a) (b)
CONDITION 7: Repeat PART 9: POST- - 12 months.
NO CRACK AND NO REPAIR INSPECTION
LOOSE OR MISSING OF THE HORIZONTAL
FASTENER FOUND IN STABILIZER LOWER
ZONE-A or ZONE-B or SKIN for any crack and
ZONE-C or ZONE-D or for any loose or any
ZONE-E or ZONE-F. missing fastener. (b) (c)
(d) (e) (f)
CONDITION 8: ANY Do PART 4: SKIN Before further flight. -
CRACK FOUND IN ZONE- SPLICE REPAIR IN
A. ZONE-A. (c)
B. ZONE-B. (d)
C. ZONE-C. (e)
D. ZONE-D. (f)
CONDITION 12: ANY Contact The Boeing Before further flight. -
CRACK FOUND IN ZONE- Company for repair in-
E or ZONE-F. structions and do the re-
pair.
CONDITION 13: ANY Do PART 10: OPEN Before further flight. -
LOOSE OR ANY MISSING HOLE INSPECTION for
FASTENER FOUND, NO any corrosion and any
CRACK FOUND IN ZONE- hole elongation and for
A OR ZONE-B OR ZONE- any crack.
C OR ZONE-D.

737-55-1059

CONDITION 14: NO COR- CONDITION 14 (ACTION Before further flight. -
ROSION, NO HOLE 1): Install new fastener.
ELONGATION AND NO (g)
CRACK FOUND IN ANY
CONDITION 14 (ACTION - 12 months.
HOLE OF LOOSE OR
2): Repeat PART 9:
MISSING FASTENERS IN
POST-REPAIR INSPEC-
REPAIRED AREAS.
TION OF THE HORIZON-
TAL STABILIZER LOW-
ER SKIN for any crack
and for any loose or any
missing fastener. (b) (c)
(d) (e) (f)
CONDITION 15: ANY CONDITION 15 (ACTION Before further flight. -
CORROSION OR ANY 1): Contact The Boeing
HOLE ELONGATION OR Company for repair in-
ANY CRACK FOUND IN structions and do the re-
ANY HOLE OF LOOSE OR pair.
MISSING FASTENERS IN
CONDITION 15 (ACTION - 12 months.
REPAIRED AREAS.
2): Repeat PART 9:
POST-REPAIR INSPEC-
TION OF THE HORIZON-
TAL STABILIZER LOW-
ER SKIN for any crack
and for any loose or any
missing fastener. (b) (c)
(d) (e) (f)
(a) Prior to the release date of SB 737-55-1059 Revision 1, if a Boeing ODA FAA Form 8100-9 approved
skin splice repair was installed, and the splice and replaced segment of skin is in the same location as
the part 4, part 5, part 6, or part 7 skin splice repair given in paragraph 3.B., Work Instructions of this
service bulletin, then the corresponding paragraph 3.A., General Information note regarding inspection
termination applies.
(b) Doublers installed with solid rivets do not need to be inspected for any loose or any missing fasteners.
(c) Accomplishment of PART 4: SKIN SPLICE REPAIR IN ZONE-A is terminating action to the inspections
(d) Accomplishment of PART 5: SKIN SPLICE REPAIR IN ZONE-B is terminating action to the inspections
(e) Accomplishment of PART 6: SKIN SPLICE REPAIR IN ZONE-C is terminating action to the inspections
(f) Accomplishment of PART 7: SKIN SPLICE REPAIR IN ZONE-D is terminating action to the inspections

737-55-1059

(g) For repairs installed in accordance with an SRM, install new fastener in accordance with 737-300 SRM
55-10-01, Repair 13 or 737-400 SRM 55-10-01, Repair 13 or 737-500 SRM 55-10-01, Repair 13. For
repairs installed in accordance with FIGURE 4 of this service bulletin, install new fastener in accordance
with FIGURE 4 of this service bulletin. Only non-solid rivet repairs are being inspected.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations 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.
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.
G. Manpower
The table below shows an estimate of the man-hours necessary to do this inspection, repair 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.
PART 1: DETAILED INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN
Task Number of Persons Man-Hours Elapsed Time (Hours)

FIGURE 1 1 0.75 0.75
FIGURE 2 1 0.75 0.75
TOTAL FOR EACH AIRPLANE 1.50 1.50

737-55-1059
PART 2: PREVENTIVE MODIFICATION IN ZONE-A

Access - OPTION 1 4 20.00 5.00
Modify 1 2.25 2.25
Close 4 28.00 7.00
TOTAL FOR EACH STABILIZER 50.25 14.25
Modify 1 2.25 2.25
Close 4 7.00 1.75
PART 3: PREVENTIVE MODIFICATION IN ZONE-B

Modify 1 2.25 2.25
Close 4 28.00 7.00
Modify 1 2.25 2.25
Close 4 7.00 1.75
PART 4: SKIN SPLICE REPAIR IN ZONE-A

Repair 4 49.00 12.25
Close 4 28.00 7.00
TOTAL FOR LEFT STABILIZER 97.00 24.25
Repair 4 49.00 12.25
Close 4 7.00 1.75

737-55-1059
PART 5: SKIN SPLICE REPAIR IN ZONE-B

Access - OPTON 1 4 20.00 5.00
Repair 4 49.00 12.25
Close 4 28.00 7.00
TOTAL FOR RIGHT STABILIZER 97.00 24.25
Repair 4 49.00 12.25
Close 4 7.00 1.75
PART 6: SKIN SPLICE REPAIR IN ZONE-C

Repair 4 163.00 40.75
Close 4 28.00 7.00
Repair 4 163.00 40.75
Close 4 7.00 1.75
PART 7: SKIN SPLICE REPAIR IN ZONE-D

Repair 4 163.00 40.75
Close 4 28.00 7.00
Repair 4 163.00 40.75
Close 4 7.00 1.75

737-55-1059
PART 8: EXTERNAL DOUBLER REPAIR

FIGURE 3 1 0.25 0.25
FIGURE 4 1 1.75 1.75
Close 4 28.00 7.00
TOTAL FOR EACH REPAIR 50.00 14.00
FIGURE 9 1 2.00 2.00
FIGURE 4 1 1.75 1.75
Close 4 28.00 7.00
FIGURE 3 1 0.25 0.25
FIGURE 4 1 1.75 1.75
Close 2 5.00 2.50
FIGURE 9 1 2.00 2.00
FIGURE 4 1 1.75 1.75
Close 2 5.00 2.50
PART 9: POST-REPAIR INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN

FIGURE 5 1 0.50 0.50
FIGURE 6 or FIGURE 7 1 0.75 0.75
FIGURE 8 1 2.00 2.00

737-55-1059
PART 10: OPEN HOLE INSPECTION

Remove fastener 1 0.05 0.05
Inspection for corrosion 1 0.05 0.05
Inspection for hole elonga- 1 0.05 0.05
tion
High Frequency Eddy Cur- 1 0.05 0.05
rent (HFEC) inspection for
any crack
Install fastener 1 0.05 0.05
TOTAL FOR EACH HOLE 0.25 0.25
H. Weight and Balance Changes
The weight and balance changes for the 0.080 inch doubler installation on one side of the horizontal
stabilizer are:
Airplane Change in Weight (Pounds) Change in Moment (Pound-Inch-

es)
737-300 +2.3 +3,000
737-400 +2.3 +3,000
737-500 +2.3 +3,000
The weight and balance changes for the preventive modification in either Zone-A or Zone-B on one
side of the horizontal stabilizer are:

es)
737-300 +0.2 +249.3
737-400 +0.2 +259.2
737-500 +0.2 +241.3

737-55-1059
The weight and balance changes for the skin splice repair in ZONE-A are:
Change in Weight (Pounds) Change in Moment (Pound-Inch-

Airplane es)
737-300 +0.9 +1,200
737-400 +0.9 +1,200
737-500 +0.9 +1,200
The weight and balance changes for the skin splice repair in ZONE-B are:

es)
737-300 +0.9 +1,200
737-400 +0.9 +1,200
737-500 +0.9 +1,200
The weight and balance changes for the skin splice repair in ZONE-C are:

es)
737-300 +3.1 +4,000
737-400 +3.1 +4,000
737-500 +3.1 +4,000
The weight and balance changes for the skin splice repair in ZONE-D are:

es)
737-300 +3.1 +4,000
737-400 +3.1 +4,000
737-500 +3.1 +4,000
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Boeing Service Related Problem (SRP) 737-SRP-55-0014, 737-SRP-55-0039
b. Boeing Structural Item Interim Advisory (SIIA) 737-250

737-55-1059
c. Standard Overhaul Practices Manual (SOPM) 20-50-01
d. 737 Fleet Team Digest (FTD) 55-06003
e. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 51-00-26, Part 6, 53-30-23,
Part 6, 53-30-25, Part 6, 55-10-08
f. 737-300/400/500 Aircraft Maintenance Manual (AMM) 07-11-11, 27-21-00, 27-31-00, 27-41-11
g. 737-300 Structural Repair Manual (SRM) 51-10-02, 51-20-01, 51-40-02, 51-40-08, 51-50-02,
55-10-01
h. 737-400 Structural Repair Manual (SRM) 51-10-02, 51-20-01, 51-40-02, 51-40-08, 51-50-02,
55-10-01
i. 737-500 Structural Repair Manual (SRM) 51-10-02, 51-20-01, 51-40-02, 51-40-08, 51-50-02,
55-10-01
2. Data Supplied with this Service Bulletin:
a. Drawings:
Drawing No Title Sheet DCN/REV ADCN

692A5001 HORIZONTAL STABILIZER, LOWER SKIN 1 - -
- SERVICE GENERAL REPAIR
2 - -
3 - -
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
4. Process Data:
None.
K. Publications Affected
1. Publications:
Publication Chapter-Section
737 Structural Repair Manual 51-20, 51-40, 51-50, 55-10
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 Paragraph 1.E., Compliance of this service bulletin.

737-55-1059
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.

737-55-1059
BLANK PAGE

737-55-1059
2. MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in the kits in Paragraph 2.C., Parts Necessary
for Each Airplane. As an alternative, operators can purchase the kit from Boeing Spares. The Boeing
price data shown below is given for planning purposes. Supply data can be given if requested. The
kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST

RESPONDER AT FR@BOEING.COM FOR THE LATEST PRICE INFORMATION
Kit Part Number Name Unit Price as of the

Revision 1 date of
this Service Bul-
letin (US Dollars)
65C37853-66 Fastener Kit $721.00
Operators are encouraged to complete the survey provided in APPENDIX G of this service bulletin to
help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and repair procedures given in this
service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
NOTE: If purchased from Boeing, one top kit is necessary for each horizontal stabilizer. Two top
kits are necessary for each airplane. Materials given in Paragraph 2.C.2., Parts and
Materials Supplied by the Operator are also necessary.
NOTE: Fastener kit 65C37853-44 has been replaced by fastener kit 65C37853-66.
NOTE: Fastener kit 65C37853-66 is necessary to accomplish Paragraph 3.B., Work Instructions,
PART 8: EXTERNAL DOUBLER REPAIR.
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability .

737-55-1059
Kit 65C37853
New Part Number Qty Name Existing Part Notes
Number
-66
65C37853-66 - TOP KIT, -
RETROFIT - FAS-
TENER KIT
66-2955-11 102 WASHER -
66-2955-47 25 WASHER -
BACB30NW6K10 2 BOLT - (a)
BACB30NW6K9 2 BOLT-CSK. HEAD - (a)
BACC30M6 4 COLLAR -
NAS1399D5AB2 114 RIVET, BLIND - (a)
(a) If grip length shown is not available at Boeing, fasteners supplied in kits
may be one grip length longer than indicated. Also, if any fasteners part
numbers listed are not available or have been superseded, substitute
fasteners may be supplied in kits.
2. Parts and Materials Supplied by the Operator:
QTY Part Number Name

As Necessary 0.080 inch thick 2024-T3 Clad Aluminum Doubler
As Necessary 0.050 inch thick 2024-T3 Clad Aluminum Filler
As Necessary BMS 5-95 (a) Sealant
As Necessary BMS 10-11, Type I (a) Primer
As Necessary BMS 10-11, Type II (a) Paint
(a) See the Qualified Products List at the end of the Boeing Material Specification
(BMS) for supplier data.
NOTE: The parts listed above are only necessary to install an optional external doubler repair.

737-55-1059
Refer to 692A5001 for parts and materials necessary to accomplish skin splice repair.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
None.

737-55-1059
BLANK PAGE

737-55-1059
3. ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 737 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 737
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. Use the approved fastener, process and material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate
full threaded fasteners (screws) needed for installation in this service bulletin.
6. A Detailed Inspection is defined as: 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. Surface cleaning and elaborate procedures may be required.

737-55-1059
7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
8. Boeing Service Letter 737-SL-51-042, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
9. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
10. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
11. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
12. When more than one OPTION is given for a CONDITION, do only one of the OPTION
numbers. When more than one ACTION is given for a CONDITION number or an
OPTION number, do all of the ACTION numbers for that CONDITION number or
OPTION number.
13. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
14. Refer to APPENDIX A and APPENDIX B for logic diagrams. Logic diagrams are
provided as an aid only. Information contained in Paragraph 1.E., Compliance is the
primary source for compliance times. Information in Paragraph 3.B., Work Instructions
is the primary source for tasks required for compliance.
15. Accomplishment of PART 2: PREVENTIVE MODIFICATION IN ZONE-A or PART

3: PREVENTIVE MODIFICATION IN ZONE-B is terminating action to the inspections
16. Accomplishment of PART 4: SKIN SPLICE REPAIR IN ZONE-A is terminating action

to the inspections between SSTA 83.50 and SSTA 111.10.
17. Accomplishment of PART 5: SKIN SPLICE REPAIR IN ZONE-B is terminating action

18. Accomplishment of PART 6: SKIN SPLICE REPAIR IN ZONE-C is terminating action

19. Accomplishment of PART 7: SKIN SPLICE REPAIR IN ZONE-D is terminating action


737-55-1059
B. WORK INSTRUCTIONS
WARNING: BEFORE MOVING HORIZONTAL STABILIZER, MAKE CERTAIN THAT AREAS AROUND
HORIZONTAL STABILIZER AND ELEVATORS ARE CLEAR OF PERSONNEL AND
EQUIPMENT AND THAT UPPER TAIL CONE DOORS ARE CLOSED. THE MOVEMENT
OF SURFACES CAN CAUSE INJURIES TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNING: DEPRESSURIZE THE RUDDER, ELEVATORS, AND HORIZONTAL STABILIZER.

PRESSURE IN THESE HYDRAULIC SYSTEMS CAN ALLOW COMPONENTS TO BE
MOVED SUDDENLY BY ANOTHER PERSON. THIS CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.
1. Remove the pressure from systems A and B for the rudder. Refer to 737-300/400/500 AMM
27-21-00 as an accepted procedure.
2. Remove the pressure from the elevators. Refer to 737-300/400/500 AMM 27-31-00 as an accepted
procedure.
3. Set the stabilizer trim cutout switches to CUTOUT.
4. Open the following circuit breakers and attach DO-NOT-CLOSE tags.
a. P6 Circuit Breaker Panel:
(1) STABILIZER TRIM ACTUATOR.
(2) STABILIZER TRIM CONT.
b. P18 Circuit Breaker Panel:
(1) AUTOPILOT STABILIZER TRIM SERVO.
5. Use the stabilizer trim wheel on the control stand to set the horizontal stabilizer at zero degrees
(3 units of trim).
6. Install the trim lock assembly, F71336-501, on the stabilizer trim wheel.
a. Turn the trim wheel to put the handle at the top of the wheel.
b. Adjust the height of the trim lock to set the trim wheel handle tightly in the bottom of the yoke.
c. Install the pin through the yoke and install the safety pin.
7. Do PART 1: DETAILED INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN for

any crack.
a. CONDITION 1: NO CRACK FOUND IN ZONE-A or ZONE-B or ZONE-C or ZONE-D or ZONE-E

or ZONE-F.

737-55-1059
(1) Repeat PART 1: DETAILED INSPECTION OF THE HORIZONTAL STABILIZER LOWER

SKIN for any crack.
b. CONDITION 2: ANY CRACK FOUND IN ZONE-A.
(1) OPTION 1: Do PART 4: SKIN SPLICE REPAIR IN ZONE-A.
(2) OPTION 2: Do an external doubler repair in accordance with 737-300 SRM 55-10-01,
Repair 13 or 737-400 SRM 55-10-01, Repair 13 or 737-500 SRM 55-10-01, Repair 13.
NOTE: Refer to Table 2 for compliance information related to post-repair inspections

of SRM doubler repairs or external doubler repairs.
c. CONDITION 3: ANY CRACK FOUND IN ZONE-B.
(1) OPTION 1: Do PART 5: SKIN SPLICE REPAIR IN ZONE-B.
NOTE: Refer to Table 2 for compliance information related to post-repair inspection of

SRM doubler repair or external doubler repairs.
d. CONDITION 4: ANY CRACK FOUND IN ZONE-C.
(1) OPTION 1: Do PART 6: SKIN SPLICE REPAIR IN ZONE-C.

(3) OPTION 3: Do PART 8: EXTERNAL DOUBLER REPAIR.

NOTE: This option only applies for any crack found in ZONE-C or ZONE-D between
SSTA 111.10 and SSTA 166.30.
e. CONDITION 5: ANY CRACK FOUND IN ZONE-D.
(1) OPTION 1: Do PART 7: SKIN SPLICE REPAIR IN ZONE-D.

SSTA 105.70 and SSTA 157.10.

737-55-1059
(3) OPTION 3: Do PART 8: EXTERNAL DOUBLER REPAIR.

SSTA 111.10 and SSTA 166.30.
f. CONDITION 6: ANY CRACK FOUND IN ZONE-E OR ZONE-F.
(1) Contact The Boeing Company for repair instructions and do the repair.
EQUIPMENT.
8. Remove the stabilizer trim lock assembly, F71336-501, from the stabilizer trim wheel.
9. Set the stabilizer trim cutout switches to NORMAL.
10. Remove the DO-NOT-CLOSE tags and close the following circuit breakers.
11. Pressurize the elevator hydraulics. Refer to 737-300/400/500 AMM 27-31-00 as an accepted
procedure.
12. Pressurize the rudder hydraulics. Refer to 737-300/400/500 AMM 27-21-00 as an accepted
procedure.
13. Put the airplane back to a serviceable condition.

737-55-1059
EQUIPMENT.
WARNING: DEPRESSURIZE THE RUDDER, ELEVATORS, AND HORIZONTAL STABILIZER.

PRESSURE IN THESE HYDRAULIC SYSTEMS CAN ALLOW COMPONENTS TO BE
MOVED SUDDENLY BY ANOTHER PERSON. THIS CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.
1. Remove the pressure from systems A and B for the rudder. Refer to 737-300/400/500 AMM
27-21-00 as an accepted procedure.
2. Remove the pressure from the elevators. Refer to 737-300/400/500 AMM 27-31-00 as an accepted
procedure.
3. Set the stabilizer trim cutout switches to CUTOUT.
4. Open the following circuit breakers and attach DO-NOT-CLOSE tags.
5. Use the stabilizer trim wheel on the stabilizer trim wheel to set the horizontal stabilizer at zero
degrees (3 units of trim).
6. Install the trim lock assembly, F71336-501, on the stabilizer trim wheel.
a. Turn the trim wheel to put the handle at the top of the wheel.
b. Adjust the height of the trim lock to set the trim wheel handle tightly in the bottom of the yoke.
c. Install the pin through the yoke and install the safety pin.
7. Do PART 9: POST-REPAIR INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN

for any crack and for any loose or any missing fastener.
NOTE: Prior to the release date of SB 737-55-1059 Revision 1, if a Boeing ODA FAA Form
8100-9 approved skin splice repair was installed, and the splice and replaced segment
of skin is in the same location as the part 4, part 5, part 6, or part 7 skin splice repair
given in paragraph 3.B., Work Instructions of this service bulletin, then the corresponding
paragraph 3.A., General Information note regarding inspection termination applies.

737-55-1059
NOTE: Doublers installed with solid rivets do not need to be inspected for any loose or any
missing fasteners.
a. CONDITION 7: NO CRACK AND NO LOOSE OR MISSING FASTENER FOUND IN ZONE-A

or ZONE-B or ZONE-C or ZONE-D or ZONE-E or ZONE-F.
(1) Repeat PART 9: POST-REPAIR INSPECTION OF THE HORIZONTAL STABILIZER

LOWER SKIN for any crack and for any loose or any missing fastener.
NOTE: Doublers installed with solid rivets do not need to be inspected for any loose or
any missing fasteners.
b. CONDITION 8: ANY CRACK FOUND IN ZONE-A.
(1) Do PART 4: SKIN SPLICE REPAIR IN ZONE-A.
c. CONDITION 9: ANY CRACK FOUND IN ZONE-B.
(1) Do PART 5: SKIN SPLICE REPAIR IN ZONE-B.
d. CONDITION 10: ANY CRACK FOUND IN ZONE-C.
(1) Do PART 6: SKIN SPLICE REPAIR IN ZONE-C.
e. CONDITION 11: ANY CRACK FOUND IN ZONE-D.
(1) Do PART 7: SKIN SPLICE REPAIR IN ZONE-D.
f. CONDITION 12: ANY CRACK FOUND IN ZONE-E OR ZONE-F.
(1) Contact The Boeing Company for repair instructions and do the repair.
g. CONDITION 13: ANY LOOSE OR ANY MISSING FASTENER FOUND, NO CRACK FOUND
IN ZONE-A OR ZONE-B OR ZONE-C OR ZONE-D.
(1) Do PART 10: OPEN HOLE INSPECTION for any corrosion and any hole elongation and
for any crack.
(a) CONDITION 14: NO CORROSION, NO HOLE ELONGATION AND NO CRACK

FOUND IN ANY HOLE OF LOOSE OR MISSING FASTENERS IN REPAIRED
AREAS.
1) CONDITION 14 (ACTION 1): Install new fastener.
NOTE: For repairs installed in accordance with an SRM, install new fastener
in accordance with 737-300 SRM 55-10-01, Repair 13 or 737-400 SRM
55-10-01, Repair 13 or 737-500 SRM 55-10-01, Repair 13. For repairs
installed in accordance with FIGURE 4 of this service bulletin, install
new fastener in accordance with FIGURE 4 of this service bulletin. Only
non-solid rivet repairs are being inspected.

737-55-1059
2) CONDITION 14 (ACTION 2): Repeat PART 9: POST-REPAIR INSPECTION

OF THE HORIZONTAL STABILIZER LOWER SKIN for any crack and for any
loose or any missing fastener.
NOTE: Doublers installed with solid rivets do not need to be inspected for any
loose or any missing fasteners.
(b) CONDITION 15: ANY CORROSION OR ANY HOLE ELONGATION OR ANY CRACK
FOUND IN ANY HOLE OF LOOSE OR MISSING FASTENERS IN REPAIRED
AREAS.
1) CONDITION 15 (ACTION 1): Contact The Boeing Company for repair instructions
and do the repair.
2) CONDITION 15 (ACTION 2): Repeat PART 9: POST-REPAIR INSPECTION

OF THE HORIZONTAL STABILIZER LOWER SKIN for any crack and for any
loose or any missing fastener.
NOTE: Doublers installed with solid rivets do not need to be inspected for any
loose or any missing fasteners.
EQUIPMENT.
8. Remove the stabilizer trim lock assembly, F71336-501, from the stabilizer trim wheel.
9. Set the stabilizer trim cutout switches to NORMAL.
10. Remove the DO-NOT-CLOSE tags and close the following circuit breakers.
11. Pressurize the elevator hydraulics. Refer to 737-300/400/500 AMM 27-31-00 as an accepted
procedure.
12. Pressurize the rudder hydraulics. Refer to 737-300/400/500 AMM 27-21-00 as an accepted
procedure.

737-55-1059
PART 1: DETAILED INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN
1. Do a Detailed Inspection (DI) of the inspar lower skin of the horizontal stabilizer between SSTA
83.50 and 249.10 for any crack in accordance with the figures below.
Left Horizontal Stabilizer Right Horizontal Stabilizer

FIGURE 1 FIGURE 2
PART 2: PREVENTIVE MODIFICATION IN ZONE-A
1. Do one of the following:
a. OPTION 1: Remove the horizontal stabilizer and put it on a cradle. Refer to 737-300/400/500
AMM 27-41-11 as an accepted procedure.
b. OPTION 2: Jack and shore the airplane in accordance with APPENDIX C.
NOTE: If PART 2: PREVENTIVE MODIFICATION IN ZONE-A is being done at the same time
as PART 6: SKIN SPLICE REPAIR IN ZONE-C or PART 7: SKIN SPLICE REPAIR IN
ZONE -D, do OPTION 1. If no other work is being done on the horizontal stabilizer, do
OPTION 1 or OPTION 2.
2. Make bonded skin assembly 692A5001-41 in accordance with Boeing drawing 692A5001.
3. Install made bonded skin assembly in accordance with Boeing drawing 692A5001-1.
4. If removed, install horizontal stabilizer. Refer to 737-300/400/500 AMM 27-41-11 as an accepted

procedure.
5. If the airplane was jacked and shored, remove shoring supports and jacks in accordance with
APPENDIX D.
PART 3: PREVENTIVE MODIFICATION IN ZONE-B
NOTE: If PART 3: PREVENTIVE MODIFICATION IN ZONE-B is being done at the same time
as PART 6: SKIN SPLICE REPAIR IN ZONE-C or PART 7: SKIN SPLICE REPAIR IN
ZONE -D, do OPTION 1. If no other work is being done on the horizontal stabilizer, do
OPTION 1 or OPTION 2.

737-55-1059
2. Make bonded skin assembly 692A5001-42 in accordance with Boeing drawing 692A5001.
3. Install made bonded skin assembly in accordance with Boeing drawing 692A5001-2.

procedure.
APPENDIX D.
PART 4: SKIN SPLICE REPAIR IN ZONE-A
a. OPTION 1: Remove the left side horizontal stabilizer and put it on a cradle. Refer to
737-300/400/500 AMM 27-41-11 as an accepted procedure.
CAUTION: DO NOT CUT INTO THE STRUCTURE BEHIND THE SKIN. USE CAUTION TO
PREVENT NICKS, GOUGES OR OTHER DAMAGE TO THE STRUCTURE. IF THE
STRUCTURE IS DAMAGED, MORE REPAIR WORK WILL BE NECESSARY.
2. Remove, make and install the made lower skin in accordance with Boeing drawing 692A5001-1.

procedure.
APPENDIX D.
PART 5: SKIN SPLICE REPAIR IN ZONE-B
a. OPTION 1: Remove the right side horizontal stabilizer and put it on a cradle. Refer to

procedure.

737-55-1059
APPENDIX D.
PART 6: SKIN SPLICE REPAIR IN ZONE-C
a. OPTION 1: Remove the left side horizontal stabilizer and put it on a cradle. Refer to
b. OPTION 2: Jack and shore the airplane in accordance with APPENDIX E.

procedure.
APPENDIX F.
PART 7: SKIN SPLICE REPAIR IN ZONE-D
a. OPTION 1: Remove the right side horizontal stabilizer and put it on a cradle. Refer to
b. OPTION 2: Jack and shore the airplane in accordance with APPENDIX E.

procedure.
APPENDIX F.

737-55-1059
PART 8: EXTERNAL DOUBLER REPAIR
CAUTION: THE WEIGHT OF THE HORIZONTAL STABILIZER PRE-LOADS THE LOWER SKIN
RESULTING IN DEFLECTION OF THE SKIN SURFACE. OPTION 1: REMOVAL OF
THE HORIZONTAL STABILIZER IS THE PREFERRED METHOD FOR THIS REPAIR.
CAUTION: DO NOT NOTCH OR DRILL THROUGH THE REAR SPAR CHORD OR ADJACENT
STRUCTURE WHEN THE DAMAGED SKIN IS CUT OUT OR STOP DRILLED.
a. If the crack is further than 0.50 inch from the centerline of fastener(s), stop drill the crack in
accordance with FIGURE 3.
b. If the crack is 0.50 inch or closer from the centerline of fastener(s), cut out the damaged area
in accordance with FIGURE 9.
3. Install an external doubler in accordance with FIGURE 4. The repair is similar to 737-300 SRM
55-10-01 Repair 13, 737-400 SRM 55-10-01 Repair 13, 737-500 SRM 55-10-01 Repair 13.

procedure.
5. If the airplane was jacked and shored, remove shoring and jacks in accordance with APPENDIX
D.
PART 9: POST-REPAIR INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN
1. Do a High Frequency Eddy Current (HFEC) inspection of the skin around any SRM repair or any
external doubler repair for any crack and a Detailed Inspection of repaired doublers for any loose
or any missing fastener in accordance with FIGURE 5.
NOTE: Doublers installed with solid rivets do not need to be inspected for any loose or any
missing fastener.
2. Do a Detailed Inspection of the inspar lower skin of the horizontal stabilizer in unrepaired areas
for any crack in accordance with the figures below:
Left Horizontal Stabilizer Right Horizontal Stabilizer

FIGURE 6 FIGURE 7

737-55-1059
3. Do a Low Frequency Eddy Current (LFEC) inspection of the forward fastener row of any external
doubler repair for any crack in accordance with FIGURE 8.
PART 10: OPEN HOLE INSPECTION
1. Remove any loose fastener.
2. Do a Detailed Inspection of open holes for any corrosion.
3. Do a Detailed Inspection of open holes for any hole elongation.
4. Do a High Frequency Eddy Current (HFEC) inspection of open holes in accordance with 737 NDT
Manual Part 6, 51-00-00 Procedure 11 or Procedure 16 for any crack.

737-55-1059
This Figure applies only to: Group 1, Configuration 1.
FIGURE 1: LEFT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION

(SHEET 1 OF 2)
Revision 1 April 06, 2016 PROPRIETARY - Copyright © Unpublished
737-55-1059
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Inspect Lower surface skin Detailed Inspec- - (a) (b)
tion
(a) Do a Detailed Inspection for any crack.
(b) As an option to the Detailed Inspection, do a High Frequency Eddy Current (HFEC) inspection in ac-
cordance with 737 NDT Manual Part 6, 51-00-00, Procedure 23, and one of the following: (i) a Medium
Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT Manual Part 6, 53-30-23;
(ii) a C-Scan inspection in accordance with 737 NDT Manual Part 6, 53-30-25 using reference standard
NDT1097-B; (iii) a Magneto Optical Imaging (MOI) inspection in accordance with 737 NDT Manual
Part 6, 55-10-08 for any crack.
FIGURE 1: LEFT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION

(SHEET 2 OF 2)
737-55-1059
FIGURE 2: RIGHT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION

(SHEET 1 OF 2)
737-55-1059
Step Task Name Identification Qty More Data

1 Inspect Lower surface skin - - (a) (b)
(a) Do a Detailed Inspection of the outer surface for any crack. The inspection area is from 0.30 inch radius
from the center of each fastener and from 0.10 inch from the centerline of the forward fastener row to
1.50 inch forward of the forward fastener row centerline of the rear spar-to-skin fasteners.
(b) As an option to the Detailed Inspection, do a High Frequency Eddy Current (HFEC) inspection in accor-
dance with 737 NDT Manual Part 6, 51-00-00, Procedure 23, and one of the following: (i) a Medium Fre-
quency Eddy Current (MFEC) inspection in accordance with 737 NDT Manual Part 6, 53-30-23; (ii) a C-
Scan inspection in accordance with 737 NDT Manual Part 6, 53-30-25 using reference standard NDT1097-
B; (iii) a Magneto Optical Imaging (MOI) inspection in accordance with 737 NDT Manual Part 6, 55-10-08
for any crack.
FIGURE 2: RIGHT HORIZONTAL STABILIZER LOWER SKIN - DETAILED INSPECTION

(SHEET 2 OF 2)
737-55-1059
STEP TASK NAME PART NUMBER QTY NOTES

1 Drill Damage - - (a) (b)
(a) Do not drill through the rear spar chord or adjacent structure. Use a 0.020 inch thick corrosion resistant
steel sacrificial sheet to prevent damage.
(b) Stop drill the crack with 0.25 inch diameter holes. Refer to 737-300 SRM 51-10-02 or 737-400 SRM 51-
10-02 or 737-500 SRM 51-10-02 as an accepted procedure.
FIGURE 3: STOP DRILL REPAIR

(SHEET 1 OF 1)
737-55-1059
FIGURE 4: EXTERNAL DOUBLER REPAIR INSTALLATION

(SHEET 1 OF 4)
737-55-1059

(SHEET 2 OF 4)
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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one repair.
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Fasteners - - Remove carefully to reduce the
need for oversize replacement
fasteners.
2 Make Doubler - - Make from 0.080 inch 2024-T3
clad aluminum sheet.
3 Chamfer Edges - - Chamfer all four edges. See View
A-A.
4 Clamp Doubler - - Maximum gap between parts be-
fore fastener installation is 0.010
inch.
5 Drill Holes - - Match drill using a template and,
where access is possible, back-
drill using existing fastener holes.
6 Mark Holes - - Mark new fastener holes.
Drill Holes - - -
7 Apply Chemical Conversion Alodine - Refer to 737-300 SRM 51-20-01
Coating Solution or 737-400 SRM 51-20-01 or 737-
500 SRM 51-20-01 as an accept-
Primer BMS 10-11, Type I -
ed procedure.
Enamel BMS 10-11, Type II - Color to match adjacent structure.
8 Install Doubler - - Fay seal and install fasteners wet
using BMS 5-95.
9 Apply Fillet Seal - - Around edges of doubler, BMS
5-95.
CAUTION: Make sure the distance from the fastener to the edge of the chem-mill is 0.375 inch.

(SHEET 3 OF 4)
737-55-1059
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener.
CODE NAME PART NUMBER HOLE DIA NOTES

A Rivet NAS1399D6AB( ) 0.190 - 0.198 (a)
Countersink Washer 66-2955-11 (b)
B Rivet NAS1399D5AB( ) 0.159 - 0.167 (a)
Countersink Washer 66-2955-47 (b) (c)
C Bolt BACB30NW6K( ) 0.1953 - 0.1960 Install bolt with BMS 5-95. Use
0.0156 inch oversized fasteners if
necessary.
Countersink Washer 66-2955-11 (b)
Collar BACC30M6 -
(a) If desired, you can install access panels in the lower skin. Refer to 737-300 SRM 55-10-01, Figure
201, or 737-400 SRM 55-10-01, Figure 201, or 737-500 SRM 55-10-01, Figure 201 as an accepted
procedure. Install blind rivets wet with sealant BMS 5-95.
(b) Refer to 737-300 SRM 51-40-08 or 737-400 SRM 51-40-08 or 737-500 SRM 51-40-08 as an accepted
procedure.
(c) NAS1399D5A2 rivets are installed without washers.

(SHEET 4 OF 4)
737-55-1059
FIGURE 5: HORIZONTAL STABILIZER LOWER SKIN SRM REPAIR OR EXTERNAL DOUBLER REPAIR -
POST-REPAIR INSPECTION
(SHEET 1 OF 2)
737-55-1059

2 Inspect Lower surface skin - - (c)
3 Inspect External Repair Dou- - - (d)
bler
(a) The inspection area extends two bays to the inboard and outboard side of the repaired bay.
(b) Do a High Frequency Eddy Current (HFEC) inspection for any crack in accordance with 737 NDT Manual
Part 6, 51-00-00, Procedure 23. As an option, also do a Medium Frequency Eddy Current (MFEC) inspec-
tion in accordance with 737 NDT Manual Part 6, 53-30-23; or a C-Scan inspection in accordance with
737 NDT Manual Part 6, 53-30-25 using reference standard NDT1097-B; or a Magneto Optical Imaging
(MOI) inspection in accordance with 737 NDT Manual Part 6, 55-10-08 for any crack.
(c) Do a High Frequency Eddy Current (HFEC) inspection of the skin around the edge of the repair doubler
for any crack in accordance with 737 NDT Manual Part 6, 51-00-00, Procedure 23.
(d) Do a Detailed Inspection for any loose or any missing fastener.
FIGURE 5: HORIZONTAL STABILIZER LOWER SKIN SRM REPAIR OR EXTERNAL DOUBLER REPAIR -
POST-REPAIR INSPECTION
(SHEET 2 OF 2)
737-55-1059

INSPECTION
(SHEET 1 OF 2)
737-55-1059

(a) Do a Detailed Inspection for any crack. If an SRM repair or external doubler repair is present, do not do
a Detailed Inspection of the repaired area but do a High Frequency Eddy Current (HFEC) inspection of
the repaired area in accordance with FIGURE 5.
for any crack.

INSPECTION
(SHEET 2 OF 2)
737-55-1059

INSPECTION
(SHEET 1 OF 2)
737-55-1059

(a) Do a Detailed Inspection for any crack. If an SRM repair or external doubler repair is present, do not do
a Detailed Inspection of the repaired area but do a High Frequency Eddy Current (HFEC) inspection of
the repaired area in accordance with FIGURE 5.
for any crack.

INSPECTION
(SHEET 2 OF 2)
737-55-1059
CURRENT INSPECTION
(SHEET 1 OF 3)
737-55-1059
CURRENT INSPECTION
(SHEET 2 OF 3)
737-55-1059

1 Inspect External Repair Dou- - - (a)
bler
(a) Do a Low Frequency Eddy Current (LFEC) inspection in accordance with 737 NDT Manual Part 6, 51-00-
26 for any crack.
CURRENT INSPECTION
(SHEET 3 OF 3)
737-55-1059

1 Remove Fasteners - - (a)
2 Remove Crack damaged skin - - (b)
3 Make Filler 0.050 INCH THICK - (c)
2024-T3 CLAD ALU-
MINUM
4 Clean/Deburr Filler 0.050 INCH THICK - Break sharp edges
2024-T3 CLAD ALU- of 0.015-0.030 inch
MINUM radius.
Clean/Deburr Lower surface skin - - Break sharp edges
of 0.015-0.030 inch
radius.
FIGURE 9: CUT OUT REPAIR

(SHEET 1 OF 2)
737-55-1059

5 Drill Filler 0.050 INCH THICK - Match drill holes.
2024-T3 CLAD ALU-
MINUM
6 Install (New) Filler 0.050 INCH THICK - Fay seal using BMS
2024-T3 CLAD ALU- 5-95.
MINUM
Apply Sealant BMS 5-95 - Fill gap around filler.
(a) In accordance with 737-300 SRM 51-40-02 or 737-400 SRM 51-40-02 or 737-500 SRM 51-40-02.
(b) Do not notch the rear spar chord or adjacent structure when the damaged skin is cut out. Use a 0.020
inch thick corrosion resistant steel sacrificial sheet to prevent damage.
(c) Maintain a 0.50 inch minimum cutout radius, and a surface smoothness of 63 microinches or smoother
on all surfaces.
FIGURE 9: CUT OUT REPAIR

(SHEET 2 OF 2)
737-55-1059
This Appendix applies only to: Group 1, Configuration 1.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Title Description
PART 1 DETAILED INSPECTION OF THE HORIZONTAL STABILIZER LOWER SKIN
for any crack.
PART 4 SKIN SPLICE REPAIR IN ZONE-A.
PART 5 SKIN SPLICE REPAIR IN ZONE-B.
PART 6 SKIN SPLICE REPAIR IN ZONE-C.
PART 7 SKIN SPLICE REPAIR IN ZONE-D.
PART 8 EXTERNAL DOUBLER REPAIR.
CONDITION 1 NO CRACK FOUND IN ZONE-A or ZONE-B or ZONE-C or ZONE-D or ZONE-
E or ZONE-F.
CONDITION 2 ANY CRACK FOUND IN ZONE-A.
CONDITION 3 ANY CRACK FOUND IN ZONE-B
CONDITION 4 ANY CRACK FOUND IN ZONE-C.
CONDITION 5 ANY CRACK FOUND IN ZONE-D.
CONDITION 6 ANY CRACK FOUND IN ZONE-E OR ZONE-F.
2. The table below gives the description for the flag notes called out in the logic diagram.
Flag Note Letter Description

(a) Accomplishment of PART 4: SKIN SPLICE REPAIR IN ZONE-A is terminating
action to the inspections between SSTA 83.50 and SSTA 111.10.
(b) Accomplishment of PART 5: SKIN SPLICE REPAIR IN ZONE-B is terminating
(c) Accomplishment of PART 6: SKIN SPLICE REPAIR IN ZONE-C is terminating
(d) Accomplishment of PART 7: SKIN SPLICE REPAIR IN ZONE-D is terminating
(e) Accomplishment of PART 2: PREVENTIVE MODIFICATION IN ZONE-A or
PART 3: PREVENTIVE MODIFICATION IN ZONE-B is terminating action to
the inspections between SSTA 83.50 and SSTA 101.90.
HORIZONTAL STABILIZER LOWER SKINS THAT DO NOT HAVE A REPAIR INSTALLED – INSPECTION
AND REPAIR
(SHEET 1 OF 5)
737-55-1059

(f) Refer to Table 2 for compliance information related to post-repair inspections
of SRM doubler repairs or external doubler repairs.
(g) Do the repair in accordance with 737-300 SRM 55-10-01, Repair 13 or 737-
400 SRM 55-10-01, Repair 13 or 737-500 SRM 55-10-01, Repair 13.
(h) This option only applies for any crack found in ZONE-C or ZONE-D between
SSTA 105.70 and SSTA 157.10.
(i) This option only applies for any crack found in ZONE-C or ZONE-D between
SSTA 111.10 and SSTA 166.30.
AND REPAIR
(SHEET 2 OF 5)
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AND REPAIR
(SHEET 3 OF 5)
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AND REPAIR
(SHEET 4 OF 5)
737-55-1059
AND REPAIR
(SHEET 5 OF 5)
737-55-1059
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Title Description
PART 4 SKIN SPLICE REPAIR IN ZONE-A.
PART 5 SKIN SPLICE REPAIR IN ZONE-B.
PART 6 SKIN SPLICE REPAIR IN ZONE-C.
PART 7 SKIN SPLICE REPAIR IN ZONE-D.
PART 9 POST-REPAIR INSPECTION OF THE HORIZONTAL STABILIZER LOWER
SKIN for any crack and for any loose or any missing fastener.
PART 10 OPEN HOLE INSPECTION for any corrosion and any hole elongation and
for any crack.
CONDITION 7 NO CRACK AND NO LOOSE OR MISSING FASTENER FOUND IN ZONE-
A or ZONE-B or ZONE-C or ZONE-D or ZONE-E or ZONE-F.
CONDITION 8 ANY CRACK FOUND IN ZONE-A.
CONDITION 9 ANY CRACK FOUND IN ZONE-B.
CONDITION 10 ANY CRACK FOUND IN ZONE-C.
CONDITION 11 ANY CRACK FOUND IN ZONE-D.
CONDITION 12 ANY CRACK FOUND IN ZONE-E or ZONE-F.
CONDITION 13 ANY LOOSE OR ANY MISSING FASTENER FOUND, NO CRACK FOUND
IN ZONE-A OR ZONE-B OR ZONE-C OR ZONE-D.
CONDITION 14 NO CORROSION, NO HOLE ELONGATION AND NO CRACK FOUND IN
ANY HOLE OF LOOSE OR MISSING FASTENERS IN REPAIRED AREAS.
CONDITION 15 ANY CORROSION OR ANY HOLE ELONGATION OR ANY CRACK FOUND
IN ANY HOLE OF LOOSE OR MISSING FASTENERS IN REPAIRED AREAS.
HORIZONTAL STABILIZER LOWER SKINS WITH AN EXISTING REPAIR INSTALLED - POST-REPAIR
INSPECTION AND REPAIR
(SHEET 1 OF 4)
737-55-1059
2. The table below gives the description for the flag notes called out in the logic diagram.

(a) Prior to the release date of SB 737-55-1059 Revision 1, if a Boeing ODA FAA
Form 8100-9 approved skin splice repair was installed, and the splice and
replaced segment of skin is in the same location as the part 4, part 5, part 6,
or part 7 skin splice repair given in paragraph 3.B., Work Instructions of this
service bulletin, then the corresponding paragraph 3.A., General Information
note regarding inspection termination applies.
(b) Doublers installed with solid rivets do not need to be inspected for any loose
or any missing fasteners.
(c) Accomplishment of PART 4: SKIN SPLICE REPAIR IN ZONE-A is terminating
(d) Accomplishment of PART 5: SKIN SPLICE REPAIR IN ZONE-B is terminating
(e) Accomplishment of PART 6: SKIN SPLICE REPAIR IN ZONE-C is terminating
(f) Accomplishment of PART 7: SKIN SPLICE REPAIR IN ZONE-D is terminating
(g) For repairs installed in accordance with an SRM, install new fastener in accor-
dance with 737-300 SRM 55-10-01, Repair 13 or 737-400 SRM 55-10-01,
Repair 13 or 737-500 SRM 55-10-01, Repair 13. For repairs installed in accor-
dance with FIGURE 4, install new fastener in accordance with FIGURE 4.
Only non-solid rivet repairs are being inspected.
(SHEET 2 OF 4)
737-55-1059
(SHEET 3 OF 4)
737-55-1059
(SHEET 4 OF 4)
737-55-1059
1. Install jacks at Main Jacking Point A, Main Jacking Point B, Main Jacking Point C, and Auxiliary Jacking
Point D. Refer to 737-300/400/500 AMM 07-11-11 as an accepted procedure.
2. Install a Horizontal Stabilizer Supplementary Support at left horizontal SSTA 166.3. Refer to 737-300
SRM 51-50-02 or 737-400 SRM 51-50-02 or 737-500 SRM 51-50-02, Figure 3, Detail View II or
equivalent for an acceptable type support.
3. Install a Horizontal Stabilizer Supplementary Support at right horizontal SSTA 166.3. Refer to 737-300
APPENDIX C: INBOARD SKIN SPLICE REPAIRS - JACKING AND SHORING

(SHEET 1 OF 1)
737-55-1059
1. Remove Horizontal Stabilizer Supplementary Support at right horizontal SSTA 166.3 in accordance
with 737-300 SRM 51-50-02 or 737-400 SRM 51-50-02 or 737-500 SRM 51-50-02, Figure 3.
2. Remove Horizontal Stabilizer Supplementary Support at left horizontal SSTA 166.3 in accordance with
737-300 SRM 51-50-02 or 737-400 SRM 51-50-02 or 737-500 SRM 51-50-02, Figure 3.
3. Remove jacks at Main Jacking Point A, Main Jacking Point B, Main Jacking Point C, and Auxiliary
Jacking Point D. Refer to 737-300/400/500 AMM 07-11-11 as an accepted procedure.
APPENDIX D: INBOARD SKIN SPLICE REPAIRS - JACKS AND SHORING SUPPORT - REMOVAL
(SHEET 1 OF 1)
737-55-1059
1. Install jacks at Main Jacking Point A, Main Jacking Point B, Main Jacking Point C, and Auxiliary Jacking
Point D. Refer to 737-300/400/500 AMM 07-11-11 as an accepted procedure.
2. Install a Horizontal Stabilizer Supplementary Support at left horizontal SSTA 193.9. Refer to 737-300
3. Install a Horizontal Stabilizer Supplementary Support at right horizontal SSTA 193.9. Refer to 737-300
APPENDIX E: OUTBOARD SKIN SPLICE REPAIRS - JACKING AND SHORING

(SHEET 1 OF 1)
737-55-1059
3. Remove jacks at Main Jacking Point A, Main Jacking Point B, Main Jacking Point C, and Auxiliary
Jacking Point D. Refer to 737-300/400/500 AMM 07-11-11 as an accepted procedure.
APPENDIX F: OUTBOARD SKIN SPLICE REPAIRS - JACKS AND SHORING SUPPORT - REMOVAL
(SHEET 1 OF 1)
737-55-1059
APPENDIX G: BOEING PART DEMAND INTENT

(SHEET 1 OF 1)
737-55-1059

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Commercial

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Inspection and Repair

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Original Issue: September 10, 1998

Original Issue: September 10, 1998

Original Issue: September 10, 1998

FIGURE 7: RIGHT HORIZONTAL STABILIZER LOWER SKIN OF UNREPAIRED AREAS - POST-REPAIR

Original Issue: September 10, 1998

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Inspection and Repair

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Group Condition Action

REASON FOR REVISION

These sections were changed:

2. In Action, in the Summary section, changed instructions.

3. In Effectivity, in the Summary section, updated reference.

4. In Compliance, in the Summary section, removed information and added reference.

5. In Industry Support Information, in the Summary section, added warranty information.

6. In Manpower, in the Summary section, removed paragraph and added reference.

Original Issue: September 10, 1998

16. In Paragraph 1.J.1., References, updated existing data.

18. In Paragraph 1.K.1., Publications, added affected publication.

21. In Paragraph 1.M., Software Accomplishment Summary, added effect.

23. In Paragraph 2.B., Industry Support Information, added warranty information.

Original Issue: September 10, 1998

28. Figure 2, added new figure for inspections.

29. Figure 3, separated repairs and moved to correct sequence.

30. Figure 4, changed fastener codes and added views.

31. In Figure 5, added post-repair inspection.

35. In Figure 9, added repair as a separate figure.

36. Appendices A and B, added logic diagrams for compliance.

41. Appendix G, added Boeing Part Demand Intent.

Pages with no vertical lines have no important changes.

Original Issue: September 10, 1998

Original Issue: September 10, 1998

Original Issue: September 10, 1998

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Inspection and Repair

Original Issue: September 10, 1998

Planning Data Affected Reference

Original Issue: September 10, 1998

Refer to Paragraph 1.E., Compliance .

INDUSTRY SUPPORT INFORMATION

Refer to Paragraph 1.G., Manpower.

Boeing Supplied Kits/Parts.

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

Original Issue: September 10, 1998

Original Issue: September 10, 1998

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Inspection and Repair

GROUP CONFIGURATION DESCRIPTION

1 - 737-300/-400/-500 airplanes. Line number 1001 to 3132.

1 Left and right horizontal stabilizer lower skins in Zone-A to Zone-F

2 Left and right horizontal stabilizer lower skins in Zone-A to Zone-F

737-300, 737-400, 737-500

Original Issue: September 10, 1998

Variable Number Group

Original Issue: September 10, 1998

Variable Number Group

Original Issue: September 10, 1998