SB-737-55-1096-00

Commercial
Airplanes
737
Service Bulletin
Number: 737-55-1096
Original Issue: March 22, 2013
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Cracking and Modification
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 © 2013 Boeing.
Unpublished Work. All Rights Reserved.
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Boeing Company.
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737-55-1096
1 of 91
2.0
BOEING SERVICE BULLETIN 737-55-1096
BLANK PAGE

Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
737-55-1096
Work - See page 1 for details. 2 of 91
Table of Contents
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 31
K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 33
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 . . . . . . . . . . . . . . . . . . . . . . . 38
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FIGURE 1: LEFT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL . . . . . . . . . . . . 49
FIGURE 2: LEFT SIDE HORIZONTAL STABILIZER - INTERNAL STRUCTURE INSPECTION . . . . 51
FIGURE 3: LEFT SIDE HORIZONTAL STABILIZER - MODIFICATION SKIN INSTALLATION . . . . 52
FIGURE 4: RIGHT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL . . . . . . . . . . . 58
FIGURE 5: RIGHT SIDE HORIZONTAL STABILIZER - INTERNAL STRUCTURE INSPECTION . . . 60
FIGURE 6: RIGHT SIDE HORIZONTAL STABILIZER - MODIFICATION SKIN INSTALLATION . . . . 61
FIGURE 7: LEFT SIDE HORIZONTAL STABILIZER LOWER SKIN MODIFICATION - POST MODIFICATION
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
FIGURE 8: RIGHT SIDE HORIZONTAL STABILIZER LOWER SKIN MODIFICATION - POST
MODIFICATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

737-55-1096
FIGURE 9: LEFT SIDE HORIZONTAL STABILIZER - FRONT SPAR UPPER CHORD - POST
FIGURE 10: RIGHT SIDE HORIZONTAL STABILIZER - FRONT SPAR UPPER CHORD - POST
APPENDIX A: FASTENER INSTALLATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . 89
APPENDIX B: FUEL BURN PENALTY ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

737-55-1096
Commercial
Airplanes
737
Service Bulletin
Number: 737-55-1096 Summary
ATA System: 5510
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Accomplishment of the modification given in this service bulletin will help prevent future cracks from occurring
in the horizontal stabilizer lower skin affected area. This service bulletin includes instructions to install a thicker
lower skin to reduce stresses to levels which preclude skin cracking. The root cause of cracking of the lower
skin has been identified as skin buckling. Cracking of the horizontal stabilizer lower skin can lead to unscheduled
downtime and maintenance.
Boeing has received numerous reports on multiple airplanes of cracks in the left and right side horizontal stabilizer
lower skin. The airplanes had accumulated an average of 22528 flight hours and 13016 flight cycles. The cracks
in the lower skin normally run in a forward to aft direction adjacent to the ribs installed between Stabilizer Station
(STAB STA) 83.50 to 184.70. Cracks have also been found forward of the rear spar in an inboard to outboard
direction.
Boeing has also received numerous reports of cracks found in the STAB STA 92.70 rib and one report of cracks
found in the STAB STA 111.10 rib. Cracks have also been found in the rib stiffeners.
Airplanes after line number 3623 have a thicker horizontal stabilizer lower skin installed at production.
All 737-700C and BBJ models that have Aviation Partners Boeing (APB) winglets installed by Supplemental
Type Certificate (STC) are excluded from this Service Bulletin.
Boeing Service Related Problem (SRP) 737NG-SRP-55-0038 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737NG FTD 55-06001 is related to this service bulletin.
Boeing did a fuel burn penalty analysis on the changes given in this service bulletin. Refer to APPENDIX B for
the analysis.
As a part of a service bulletin validation program, this modification was completed on airplanes YA091, YA004
and YA010 by Service Bulletin 737-55-1096 VC 1 before the Original Issue of this service bulletin. The modification
completed on airplanes YA091, YA004 and YA010 by Service Bulletin 737-55-1091 VC 1 is equivalent to the
Original Issue of this service bulletin. Airplanes YA091, YA004 and YA010 have the configuration of a Group 1
airplane.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.

737-55-1096
Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected
AD Related No Paragraph 1.E., Compliance
Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes
Electrical Load Changed No Paragraph 1.I., Electrical Load Data
Publications Affected Yes 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 No Paragraph 2.C.1., Kits/Parts
Operator Supplied Material Yes Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
Special Tooling Required Yes Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
ACTION (PRR 38275-153)
Work Package 1: Left Side Horizontal Stabilizer - Skin Modification
Get access to the left side horizontal stabilizer lower skin. Jack and shore the airplane. Cut the lower skin between
STAB STA 83.50 and 92.70 from the forward edge to the aft edge. Cut the lower skin between STAB STA 175.50
and 184.70 from the forward edge to the aft edge. Remove the lower skin panel. Do a detailed inspection of the
front and rear spar lower chords, ribs and rib stiffeners for cracks. If any crack is found, contact Boeing for repair
instructions and do the work instructed by Boeing or install a SRM repair, as applicable. Make and install a new
lower skin panel. At the times given in Paragraph 1.E., Compliance, do post modification detailed and eddy
current inspections of the lower modification skin area. If any crack is found, contact Boeing for repair instructions
and do the work instructed by Boeing. In addition, at the times given in Paragraph 1.E., Compliance, do post
modification eddy current inspections of the front spar upper chord. If any crack is found in the front spar upper
chord, remove the crack damage in accordance with SRM 55-10-10 or contact Boeing for repair instructions
and do the work instructed by Boeing.
Work Package 2: Right Side Horizontal Stabilizer - Skin Modification
Get access to the right side horizontal stabilizer lower skin. Jack and shore the airplane. Cut the lower skin
between STAB STA 83.50 and 92.70 from the forward edge to the aft edge. Cut the lower skin between STAB
STA 175.50 and 184.70 from the forward edge to the aft edge. Remove the lower skin panel. Do a detailed
inspection of the front and rear spar lower chords, ribs and rib stiffeners for cracks. If any crack is found, contact
Boeing for repair instructions and do the work instructed by Boeing or install a SRM repair, as applicable. Make
and install a new lower skin panel. At the times given in Paragraph 1.E., Compliance, do post modification
detailed and eddy current inspections of the lower modification skin area. If any crack is found, contact Boeing
for repair instructions and do the work instructed by Boeing. In addition, at the times given in Paragraph 1.E.,
Compliance, do post modification eddy current inspections of the front spar upper chord. If any crack is found
in the front spar upper chord, remove the crack damage in accordance with SRM 55-10-10 or contact Boeing
for repair instructions and do the work instructed by Boeing.
NOTE: Work Package 1 and Work Package 2 do not need to be done at the same time.

737-55-1096
EFFECTIVITY
737-600/-700/-700C/-800/-900/-900ER Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected
airplane(s).
COMPLIANCE
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER
Airplanes Total Task Hours Elapsed Hours

Work Package 1 132.00 (a) 35.00 (a)
Work Package 2 132.00 (a) 35.00 (a)
(a) Hours are for the modification only and does not in-
clude post modification inspection.
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.

737-55-1096

737-55-1096
Commercial
Airplanes
737
Service Bulletin
Number: 737-55-1096
ATA System: 5510
1. PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplane(s) shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR 38275-153 for data about this change.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and
Serial Number data.
GROUP CONFIGURATION DESCRIPTION
1 - 737-600/-700/-700C/-800/-900/-900ER series airplanes lines numbers

1-3623.
1 737-700, 737-800 and 737-900 airplanes with FAA APB STC

ST00830SE installed.
2 737-600, 737-700, 737-700C, 737-800, 737-900 and 737-900ER

airplanes without FAA APB STC ST00830SE installed.
Airplane Models:
737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER
Variable Number Group

YA001 - YA099 1
YA101 - YA199 1
YA201 - YA211 1
YA221 1
YA231 - YA242 1
YA251 - YA256 1
YA271 - YA272 1

737-55-1096

YA291 1
YA301 - YA302 1
YA311 - YA314 1
YA321 - YA323 1
YA336 - YA345 1
YA351 1
YA356 - YA357 1
YA366 - YA367 1
YA371 - YA377 1
YA501 - YA536 1
YA541 - YA552 1
YA571 - YA578 1
YA601 - YA615 1
YA621 - YA622 1
YA626 - YA631 1
YA635 - YA636 1
YA641 - YA642 1
YA645 - YA650 1
YA656 - YA659 1
YA666 - YA667 1
YA671 - YA672 1
YA681 - YA691 1
YA701 - YA710 1
YA721 - YA722 1
YA731 - YA734 1
YA751 - YA756 1
YA801 - YA803 1
YA809 1
YA811 - YA814 1
YA831 - YA835 1
YA841 - YA862 1
YA881 - YA882 1
YA891 - YA892 1

737-55-1096

YA961 - YA978 1
YB001 - YB006 1
YB101 - YB132 1
YB151 - YB153 1
YB156 - YB158 1
YB161 - YB164 1
YB171 - YB172 1
YB181 - YB184 1
YB201 - YB208 1
YB271 1
YB276 1
YB301 - YB310 1
YB371 - YB392 1
YB501 - YB502 1
YB521 - YB526 1
YB541 - YB544 1
YB551 1
YB561 - YB598 1
YB601 - YB635 1
YB651 1
YB656 1
YB671 - YB672 1
YB851 - YB863 1
YB871 - YB874 1
YB881 - YB893 1
YB901 - YB903 1
YB911 1
YB961 - YB975 1
YB981 1
YB986 - YB997 1
YC001 - YC030 1
YC051 - YC084 1
YC091 - YC095 1

737-55-1096

YC101 - YC104 1
YC111 - YC113 1
YC121 1
YC126 - YC127 1
YC136 - YC141 1
YC146 - YC147 1
YC151 - YC156 1
YC166 - YC171 1
YC176 - YC179 1
YC186 - YC190 1
YC201 - YC203 1
YC206 - YC207 1
YC301 - YC305 1
YC321 - YC387 1
YC391 - YC394 1
YC396 1
YC401 - YC417 1
YC421 - YC422 1
YC426 - YC428 1
YC436 - YC439 1
YC441 - YC448 1
YC451 - YC455 1
YC459 1
YC461 - YC467 1
YC471 - YC499 1
YC501 - YC526 1
YC571 - YC583 1
YC587 - YC589 1
YC591 - YC593 1
YC601 - YC655 1
YC681 - YC696 1
YC701 - YC715 1
YC720 - YC725 1

737-55-1096

YC727 - YC752 1
YC761 - YC770 1
YC781 - YC793 1
YC801 - YC892 1
YC901 - YC907 1
YC921 - YC922 1
YC931 - YC932 1
YC941 - YC951 1
YC971 - YC978 1
YC981 - YC983 1
YD001 - YD007 1
YD021 - YD025 1
YD041 - YD057 1
YD081 - YD084 1
YD101 - YD114 1
YD121 - YD126 1
YD151 - YD159 1
YD171 - YD172 1
YD201 - YD203 1
YD206 - YD209 1
YD216 - YD219 1
YD251 - YD254 1
YD256 - YD257 1
YD261 1
YD301 - YD334 1
YD391 1
YD404 - YD410 1
YD412 - YD417 1
YD481 - YD485 1
YD491 - YD499 1
YD501 - YD512 1
YD531 - YD535 1
YD541 - YD547 1

737-55-1096

YD561 - YD564 1
YD571 - YD572 1
YD591 - YD595 1
YD601 - YD612 1
YD651 - YD655 1
YE001 - YE020 1
YE051 1
YE101 - YE109 1
YE151 - YE157 1
YE171 - YE172 1
YE201 - YE206 1
YE301 - YE305 1
YE321 - YE326 1
YE371 - YE383 1
YF001 - YF011 1
YF021 - YF049 1
YF051 - YF066 1
YF086 - YF087 1
YF106 - YF107 1
YF111 - YF114 1
YF116 - YF119 1
YF121 - YF129 1
YF176 - YF178 1
YF191 - YF192 1
YF201 - YF276 1
YF401 - YF402 1
YF431 - YF432 1
YF441 - YF442 1
YF451 - YF460 1
YF501 - YF599 1
YF601 - YF621 1
YF701 - YF707 1
YF801 - YF804 1

737-55-1096

YF831 - YF832 1
YF836 - YF838 1
YF901 - YF905 1
YF921 - YF928 1
YF951 - YF952 1
YG089 1
YG104 1
YG124 - YG128 1
YG201 - YG205 1
YG211 - YG214 1
YG221 - YG224 1
YG251 - YG252 1
YG501 - YG511 1
YG601 - YG602 1
YG711 1
YH001 - YH012 1
YH031 - YH055 1
YH071 - YH080 1
YH101 - YH132 1
YH201 - YH202 1
YH206 - YH207 1
YH301 - YH306 1
YH321 - YH322 1
YH501 1
YH551 1
YJ001 - YJ013 1
YJ021 1
YJ471 - YJ480 1
YJ501 - YJ517 1
YJ531 - YJ579 1
YJ591 - YJ599 1
YJ631 - YJ632 1
YJ671 - YJ694 1

737-55-1096

YJ801 - YJ867 1
YJ871 - YJ880 1
YJ901 - YJ904 1
YJ908 - YJ929 1
YJ931 - YJ937 1
YJ941 - YJ956 1
YJ961 1
YJ976 - YJ977 1
YK001 - YK007 1
YK101 - YK104 1
YK111 - YK112 1
YK121 - YK122 1
YK131 - YK133 1
YK136 - YK139 1
YK141 - YK142 1
YK146 - YK148 1
YK151 - YK154 1
YK161 - YK167 1
YK171 1
YK176 - YK177 1
YK186 1
YK191 1
YK196 1
YK201 - YK202 1
YK301 - YK314 1
YK321 - YK340 1
YK361 - YK378 1
YK401 - YK406 1
YK426 - YK427 1
YK431 - YK450 1
YK456 - YK467 1
YK471 - YK473 1
YK476 1

737-55-1096

YK480 - YK487 1
YK491 - YK492 1
YK495 - YK498 1
YK511 - YK516 1
YK521 - YK530 1
YK551 - YK571 1
YK576 - YK577 1
YK580 - YK585 1
YK601 - YK602 1
YK606 - YK607 1
YK611 - YK616 1
YK621 - YK634 1
YK641 - YK644 1
YK651 - YK665 1
YK671 - YK672 1
YK676 - YK677 1
YK681 - YK686 1
YK691 1
YK701 - YK713 1
YK716 - YK719 1
YK721 - YK741 1
YK751 - YK770 1
YK776 - YK778 1
YK781 - YK785 1
YK791 - YK792 1
YK796 - YK797 1
YK801 - YK899 1
YK901 - YK912 1
YK918 - YK919 1
YK921 - YK928 1
YK941 - YK996 1
YL001 - YL005 1
YL011 - YL016 1

737-55-1096

YL021 - YL024 1
YL051 - YL052 1
YL056 - YL057 1
YL061 1
YL066 - YL069 1
YL076 - YL077 1
YL101 - YL137 1
YL201 - YL229 1
YL241 1
YL271 - YL272 1
YL281 - YL284 1
YL301 - YL303 1
YL311 - YL314 1
YL316 - YL321 1
YL351 - YL353 1
YL371 - YL374 1
YL401 1
YL421 - YL429 1
YL431 - YL444 1
YL461 - YL478 1
YL501 - YL509 1
YL531 - YL534 1
YL541 - YL547 1
YL561 - YL572 1
YL591 - YL598 1
YL601 - YL606 1
YL611 - YL612 1
YL616 - YL617 1
YL621 1
YL626 1
YL631 - YL634 1
YL636 - YL637 1
YL661 - YL664 1

737-55-1096

YL676 - YL681 1
YL691 1
YL696 - YL697 1
YL701 - YL707 1
YL731 1
YL751 - YL752 1
YL756 - YL757 1
YL761 - YL779 1
YL796 - YL797 1
YL801 - YL815 1
YL901 - YL910 1
YL921 - YL940 1
YL951 - YL968 1
YM101 - YM103 1
YM201 - YM244 1
YM251 - YM299 1
YM301 - YM399 1
YM401 1
YM471 1
YM481 - YM484 1
YM501 - YM515 1
YM521 - YM522 1
YM541 1
YM551 - YM553 1
YM571 - YM572 1
YM581 - YM582 1
YM591 - YM599 1
YM631 - YM634 1
YM641 - YM652 1
YM671 - YM674 1
YM691 - YM699 1
YM701 - YM710 1
YM761 - YM765 1

737-55-1096

YM771 - YM772 1
YN001 - YN016 1
YN021 - YN024 1
YN061 1
YN071 - YN082 1
YN091 - YN092 1
YN101 - YN112 1
YN121 1
YN201 - YN202 1
YN211 - YN219 1
YN231 - YN236 1
YN261 1
YN501 1
YQ001 - YQ003 1
YQ011 - YQ018 1
YQ026 - YQ029 1
YQ036 - YQ043 1
YQ201 1
YQ231 1
YQ241 - YQ248 1
YQ291 - YQ295 1
YQ301 1
YQ401 - YQ403 1
YQ451 - YQ452 1
YR001 - YR008 1
YR051 - YR054 1
YR101 1
YR111 - YR114 1
YR126 - YR128 1
YR141 1
YR166 - YR168 1
YR201 - YR204 1
YR231 - YR238 1

737-55-1096

YR271 - YR273 1
YR291 1
YR301 1
YR401 - YR403 1
YR501 - YR502 1
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Accomplishment of the modification given in this service bulletin will help prevent future cracks from
occurring in the horizontal stabilizer lower skin affected area. This service bulletin includes instructions
to install a thicker lower skin to reduce stresses to levels which preclude skin cracking. The root cause
of cracking of the lower skin has been identified as skin buckling. Cracking of the horizontal stabilizer
lower skin can lead to unscheduled downtime and maintenance.
Boeing has received numerous reports on multiple airplanes of cracks in the left and right side horizontal
stabilizer lower skin. The airplanes had accumulated an average of 22528 flight hours and 13016 flight
cycles. The cracks in the lower skin normally run in a forward to aft direction adjacent to the ribs installed
between Stabilizer Station (STAB STA) 83.50 to 184.70. Cracks have also been found forward of the
rear spar in an inboard to outboard direction.
Boeing has also received numerous reports of cracks found in the STAB STA 92.70 rib and one report
of cracks found in the STAB STA 111.10 rib. Cracks have also been found in the rib stiffeners.
Airplanes after line number 3623 have a thicker horizontal stabilizer lower skin installed at production.
All 737-700C and BBJ models that have Aviation Partners Boeing (APB) winglets installed by
Supplemental Type Certificate (STC) are excluded from this Service Bulletin.
Boeing Service Related Problem (SRP) 737NG-SRP-55-0038 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737NG FTD 55-06001 is related to this service bulletin.
Boeing did a fuel burn penalty analysis on the changes given in this service bulletin. Refer to APPENDIX
B for the analysis.
As a part of a service bulletin validation program, this modification was completed on airplanes YA091,
YA004 and YA010 by Service Bulletin 737-55-1096 VC 1 before the Original Issue of this service
bulletin. The modification completed on airplanes YA091, YA004 and YA010 by Service Bulletin
737-55-1091 VC 1 is equivalent to the Original Issue of this service bulletin. Airplanes YA091, YA004
and YA010 have the configuration of a Group 1 airplane.

737-55-1096
D. Description
Work Package 1: Left Side Horizontal Stabilizer - Skin Modification
Get access to the left side horizontal stabilizer lower skin. Cut the lower skin between STAB STA 83.50
and 92.70 from the forward edge to the aft edge. Cut the lower skin between STAB STA 175.50 and
184.70 from the forward edge to the aft edge. Remove the lower skin panel. Do a detailed inspection
of the front and rear spar lower chords, ribs and rib stiffeners for cracks. If any crack is found, contact
Boeing for repair instructions and do the work instructed by Boeing or install a SRM repair, as applicable.
Make and install a new lower skin panel. At the times given in Paragraph 1.E., Compliance, do post
modification detailed and eddy current inspections of the lower modification skin area. If any crack is
found, contact Boeing for repair instructions and do the work instructed by Boeing. In addition, at the
times given in Paragraph 1.E., Compliance, do post modification eddy current inspections of the front
spar upper chord. If any crack is found in the front spar upper chord, remove the crack damage in
accordance with SRM 55-10-10 or contact Boeing for repair instructions and do the work instructed by
Boeing.
Work Package 2: Right Side Horizontal Stabilizer - Skin Modification
Get access to the right side horizontal stabilizer lower skin. Cut the lower skin between STAB STA
83.50 and 92.70 from the forward edge to the aft edge. Cut the lower skin between STAB STA 175.50
and 184.70 from the forward edge to the aft edge. Remove the lower skin panel. Do a detailed inspection
of the front and rear spar lower chords, ribs and rib stiffeners for cracks. If any crack is found, contact
Boeing for repair instructions and do the work instructed by Boeing or install a SRM repair, as applicable.
Make and install a new lower skin panel. At the times given in Paragraph 1.E., Compliance, do post
modification detailed and eddy current inspections of the lower modification skin area. If any crack is
found, contact Boeing for repair instructions and do the work instructed by Boeing. In addition, at the
times given in Paragraph 1.E., Compliance, do post modification eddy current inspections of the front
spar upper chord. If any crack is found in the front spar upper chord, remove the crack damage in
accordance with SRM 55-10-10 or contact Boeing for repair instructions and do the work instructed by
Boeing.
NOTE: Work Package 1 and Work Package 2 do not need to be done at the same time.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones

Model Zone
737-600, 737-700, 737-700C, 331, 332, 341, 342
737-800, 737-900, 737-900ER
E. Compliance
No compliance time is given for the accomplishment of the skin modification.
Boeing recommends this service bulletin be done to introduce improvements.
Installation of the horizontal stabilizer lower skin modification affects existing Airworthiness Limitations
listed in the MPD and adds new Airworthiness Limitations at the modification splice areas. Airworthiness
Limitations are part of the 737 Type Design.

737-55-1096
Existing initial inspection thresholds are unchanged in D626A001-CMR. Existing repeat intervals are
unchanged in D626A001-DTR except for (4) Principal Structural Elements (PSE's) listed in Table 1.
These PSE's (55-10-06-2, 55-10-06-3, 55-10-06-4A and 55-10-06-4B) have the same inspections only
at more frequent repeat intervals. In addition there are new Airworthiness Limitation inspections given
in Table 1 for the modification splice areas.

737-55-1096
Table 1: Horizontal Stabilizer Lower Skin Modification - Post Modification Inspection Requirements
Condition Action Compliance Time Repeat Interval

(Not to Exceed)
Left side horizontal Do a detailed inspection of the skin, Within 56,000 flight cycles 9,000 flight cycles.
stabilizer lower modification skin and spar doublers for after installation of the modi-
skin modification cracks in accordance with Paragraph fication skin.
installed before 3.B., Work Instructions Step 3.a.
56,000 total flight
Do an eddy current inspection of the skin, Within 56,000 flight cycles 9,000 flight cycles.
cycles.
modification skin, splice doublers and after installation of the modi-
spar lower chords for cracks in accor- fication skin.
dance with Paragraph 3.B., Work Instruc-
tions Step 3.a.
Do a low frequency eddy current (LFEC) Within 56,000 flight cycles 2,000 flight cycles.
inspection of the front spar upper chord from the date of issuance of
aft flange, from STAB STA 66.50 to the original certificate of air-
STAB Tip, for cracks in accordance with worthiness or the original ex-
Paragraph 3.B., Work Instructions Step port certificate of airworthi-
3.c.(3). ness.
(a)
Do a high frequency eddy current (HFEC) Within 56,000 flight cycles 12,000 flight cy-
inspection of the front spar upper chord from the date of issuance of cles.
forward flange, from STAB STA 66.50 to the original certificate of air-
STAB Tip, for cracks in accordance with worthiness or the original ex-
Paragraph 3.B., Work Instructions Step port certificate of airworthi-
3.c.(3) ness.
(b)
Do a LFEC inspection of the front spar Within 56,000 flight cycles 11,000 flight cy-
upper chord web flange, from STAB STA from the date of issuance of cles.
66.50 to STAB STA 175.5 and from the original certificate of air-
STAB STA 258.28 to STAB Tip, for worthiness or the original ex-
cracks in accordance with Paragraph port certificate of airworthi-
3.B., Work Instructions Step 3.c.(3) ness.
(c)
Do a HFEC inspection of the front spar Within 56,000 flight cycles 11,000 flight cy-
3.B., Work Instructions Step 3.c.(3) ness.
(d)
upper chord forward flange, from STAB from the date of issuance of cles.
STA 175.5 to STAB STA 258.28, for the original certificate of air-
cracks in accordance with Paragraph worthiness or the original ex-
3.B., Work Instructions Step 3.c.(3) port certificate of airworthi-
(e) ness.

737-55-1096

(Not to Exceed)
Any crack found in Contact Boeing for repair instructions and Before further flight. -
the skin, modifica- do the work instructed by Boeing.
tion skin, spar
doublers, splice
doublers or spar
lower chords.
Any crack found in Remove the crack damage in accordance Before further flight. -
the front spar up- with Paragraph 3.B., Work Instructions
per chord. Step 3.c.(3).(a). or Contact Boeing for
repair instructions and do the work in-
structed by Boeing.

737-55-1096

(Not to Exceed)
Right side horizon- Do a detailed inspection of the skin, Within 56,000 flight cycles 9,000 flight cycles.
tal stabilizer lower modification skin and spar doublers for after installation of the modi-
installed before 3.B., Work Instructions Step 3.b.
56,000 total flight
cycles..
tions Step 3.b.
Do a LFEC inspection of the front spar Within 56,000 flight cycles 2,000 flight cycles.
upper chord aft flange, from STAB STA from the date of issuance of
66.50 to STAB Tip, for cracks in accor- the original certificate of air-
dance with Paragraph 3.B., Work Instruc- worthiness or the original ex-
tions Step 3.d.(3). port certificate of airworthi-
(a) ness.
STA 66.50 to STAB Tip, for cracks in the original certificate of air-
accordance with Paragraph 3.B., Work worthiness or the original ex-
Instructions Step 3.d.(3). port certificate of airworthi-
(b) ness.
Do a LFEC inspection of the front spar Within 56,000 flight cycles 11,000 flight cy-
3.B., Work Instructions Step 3.d.(3). ness.
(c)
3.B., Work Instructions Step 3.d.(3). ness.
(d)
STA 175.5 to STAB STA 258.28, for the original certificate of air-
cracks in accordance with Paragraph worthiness or the original ex-
3.B., Work Instructions Step 3.d.(3). port certificate of airworthi-
(e) ness.

737-55-1096

(Not to Exceed)
tion skin, spar
doublers, splice
doublers or spar
lower chords.
Any crack found in Remove the crack damage in accordance Before further flight. -
the front spar up- with Paragraph 3.B., Work Instructions
per chord. Step 3.d.(3).(a). or Contact Boeing for
repair instructions and do the work in-
structed by Boeing.
Left side horizontal Do a detailed inspection of the skin, Within 56,000 flight cycles 9,000 flight cycles.
stabilizer lower modification skin and spar doublers for after installation of the modi-
installed at or after 3.B., Work Instructions Step 3.a.
56,000 total flight
cycles.
tions Step 3.a.
Contact Boeing for additional post modi- At or before the time of lower -
fication inspections. skin modification installation.
tion skin, spar
doublers, splice
doublers or spar
lower chords.
Right side horizon- Do a detailed inspection of the skin, Within 56,000 flight cycles 9,000 flight cycles.
tal stabilizer lower modification skin and spar doublers for after installation of the modi-
installed at or after 3.B., Work Instructions Step 3.b.
56,000 total flight
cycles.
tions Step 3.b.
Contact Boeing for additional post modi- At or before the time of lower -
fication inspections. skin modification installation.

737-55-1096

(Not to Exceed)
tion skin, spar
doublers, splice
doublers or spar
lower chords.
(a) This inspection is the same as the D626A001-CMR, PSE 55-10-06-2 inspection except the repeat interval
is more frequent.
(b) This inspection is the same as the D626A001-CMR, PSE 55-10-06-3 inspection except the repeat interval
is more frequent. Inspection requires removal of the horizontal stabilizer removable leading edge.
(c) This inspection is the same as the D626A001-CMR, PSE 55-10-06-4A LFEC inspection except the repeat
interval is more frequent. Inspection requires removal of the horizontal stabilizer removable leading edge.
(d) This inspection is the same as the D626A001-CMR, PSE 55-10-06-4A HFEC inspection except the repeat
interval is more frequent. Inspection requires removal of the horizontal stabilizer removable leading edge.
(e) This inspection is the same as the D626A001-CMR, PSE 55-10-06-4B inspection except the repeat interval
is more frequent. Inspection requires removal of the horizontal stabilizer removable leading edge and re-
movable front spar web.
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.
The 737-700 airplanes that have been modified into 737-700 AEW&C by Boeing STC (ST3957SE-T,
ST01999SE, or SA10399SE-T) are not covered in this service bulletin.
This service bulletin is also approved for airplanes having FAA APB STC number ST00830SE installed.
G. Manpower
The table below shows an estimate of the task hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task 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

737-55-1096
• Time to inspect the work

• Time to cure the materials
• Time to make the parts
• Time to find the tools.
Table 1: Work Package 1 - Left Side Horizontal Stabilizer - Lower Skin Modification
Task Number of Persons Task Hours Elapsed Hours

Open Access 4 6.50 1.63
FIGURE 1 4 45.00 11.25
FIGURE 2 2 8.00 4.00
FIGURE 3 4 66.00 16.50
Close Access 4 6.50 1.63
FIGURE 7 (a) 2 28.00 14.00
FIGURE 9 Open Ac- 2 5.70 2.85
cess (a)
FIGURE 9 (a) 2 45.00 22.50
FIGURE 9 Close Ac- 2 5.70 2.85
cess (a)
TOTAL FOR EACH AIRPLANE 132.00 35.00
(a) FIGURE 7, FIGURE 9, and Figure 9 access are for post modification repeat
inspections and are not included in the total hours.
Work Package Number 1 can be done at the same time as Work Package Number 2. This manpower
estimate does not include the time required to make parts or the time for inspection of the work.
Table 2: Work Package 2 - Right Side Horizontal Stabilizer - Lower Skin Modification

Open Access 4 6.50 1.63
FIGURE 4 4 45.00 11.25
FIGURE 5 2 8.00 4.00
FIGURE 6 4 66.00 16.50
Close Access 4 6.50 1.63
FIGURE 8 (a) 2 28.00 14.00
FIGURE 10 Open 2 5.70 2.85
Access (a)
FIGURE 10 (a) 2 45.00 22.50
FIGURE 10 Close 2 5.70 2.85
Access (a)

737-55-1096
Table 2: Work Package 2 - Right Side Horizontal Stabilizer - Lower Skin Modification

TOTAL FOR EACH AIRPLANE 132.00 35.00
(a) FIGURE 8, FIGURE 10 and Figure 10 access are for post modification repeat
inspections and are not included in the total hours.
Work Package Number 2 can be done at the same time as Work Package Number 1. This manpower
estimate does not include the time required to make parts or the time for inspection of the work.
H. Weight and Balance Changes
Change in Weight Change in Moment

Airplane (Pounds) (a) (Pound-Inches) (a)
737-600 + 52.0 + 62,400.0
737-700/-700C + 52.0 + 64,500.0
737-800 + 52.0 + 70,300.0
737-900/-900ER + 52.0 + 72,500.0
(a) These figures are based on the modification being accom-
plished on both the left and right side horizontal stabilizers.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 38275-153
b. Boeing Service Letter 737-SL-51-042
c. Boeing Service Related Problem (SRP) 737NG-SRP-55-0038
d. Boeing Tooling Drawing ST1000-A-8252
e. Service Bulletin Index D6-19567
f. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-44-04, 20-50-19
g. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-26, Part 6, 53-30-00 Figure 5, Part
6, 55-10-32, Part 6, 55-10-45, Part 6, 55-10-46, Part 6, 55-10-47
h. 737-600/700/800/900 Aircraft Maintenance Manual (AMM) 06-42-00, 07-11-01, 27-31-00,

27-41-11, 27-41-21, 51-21-00
i. 737-600/700/800/900 Maintenance Planning Data (MPD) Section 9

737-55-1096
j. 737-600 Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01, 55-10-09,
55-10-10,
k. 737-700 Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01, 55-10-09,
55-10-10
l. 737-700CONV Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01,

55-10-09, 55-10-10
m. 737-700IGW (BBJ) Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01,
55-10-09, 55-10-10
n. 737-800 Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01, 55-10-09,
55-10-10
o. 737-900 Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01, 55-10-09,
55-10-10
p. 737-900ER Structural Repair Manual (SRM) 51-10-01, 51-40-08, 51-50-02, 55-10-01, 55-10-09,
55-10-10
q. 737NG Fleet Team Digest (FTD) 55-06001
2. Data Supplied with this Service Bulletin:
a. Drawings:
Drawing No Title Sheet DCN/REV ADCN

002A0001 STABILIZERS - HORIZONTAL STABILIZER 4 B -
LOWER SKIN CRACKING AND MODIFICA-
5 C -
TION
6 B -
7 C -
ST1000-A-8252 STANDARD TOOL - BUCKING BAR 1 - -
ST30-1000-CN STANDARD TOOL - CONSTRUCTION 1 W -
NOTES, BUCKING BARS AND RIVET
TOOLS
3. Installation Drawings Used in the Preparation of this Service Bulletin:
Drawing Number Title

182A4001 SKIN, LOWER - INSPAR, HORIZ STAB INSTL
182A2401 FRONT SPAR ASSY/INSTL - HORIZ STAB
182A1500 REAR SPAR ASSY/INSTL - HORIZONTAL STABILIZER
182A5301 RIB DETAIL/INSTL - INSPAR, HORIZ STAB STA 92.70
182A5302 RIB DETAIL/INSTAL - INSPAR, HORIZ STAB, STA. 101.90

737-55-1096
Drawing Number Title

182A5303 RIB DETAIL/INSTL - INSPAR, HORIZ STAB, STA 111.10
182A5304 RIB DETAIL/INSTL - INSPAR, HORIZ STAB STA 120.30
182A5404 RIB DETAIL/INSTL - INSPAR, HORIZ STAB STA. 175.50
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
Publication Chapter-Section
737 Structural Repair Manual 55-10
737 Maintenance Planning Data Section 9
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.
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.

737-55-1096
2. MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each
Airplane .
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
WORK PACKAGE 1: LEFT SIDE HORIZONTAL STABILIZER - LOWER SKIN MODIFICATION
Part Number / QTY Name Notes

Specification
2024-T3 clad 1 Modification Skin (a) (h)
sheet, 96 x 54 x
0.112 inches
2024-T3 clad 1 Splice Doubler A (a)
sheet, 54 x 9 x
0.080 inches
2024-T3 clad 1 Splice Doubler B (a)
sheet, 38 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler A (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler B (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler C (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler D (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Filler A (a)
sheet, 6 x 9 x
0.040 inches

737-55-1096

Specification
2024-T3 clad 1 Filler B (a)
sheet, 6 x 9 x
0.040 inches
2024-T3 clad 1 Filler C (a)
sheet, 6 x 9 x
0.040 inches
2024-T3 clad 1 Filler D (a)
sheet, 6 x 9 x
0.040 inches
BACR15GF6D6 965 Rivet (b) (e)
BACB30VU6K7 4 Bolt (b) (f)
BACC30BL6 24 Collar (b) (g)
BMS 10-79, TYPE 32 oz Primer (c)
3
BMS 5-95, TYPE 32 oz Sealant (c)
1, CLASS B
TYPE 2, CLASS A 32 oz Chemical Conversion Coating (d)
(a) Fabricate from 2024-T3 clad sheet in accordance with FIGURE 3.
(b) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners.
(c) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)
for supplier data.
(d) Refer to SOPM 20-43-03 for material sources.
(e) Use BACR15GF61D( ) for first oversize, if necessary. Use BACR15GF7D( ) for second
oversize, if necessary.
(f) Use BACB30NW6K( )X for first oversize, if necessary. Use BACB30NW6K( )Y for second
(g) Use BACC30M6 for first oversize, if necessary. Use BACC30R6 for second oversize, if
necessary.

737-55-1096

Specification
(h) The 2024-T3 clad sheet material for the modification skin can be purchased from the
company below:
AMI Metals Inc.
840 Industry Drive North, Suite D
Auburn, WA 98001
Cage Code: 3C3F7
Local: (253) 735-0181
Fax: (253) 735-0104
WORK PACKAGE 2: RIGHT SIDE HORIZONTAL STABILIZER - LOWER SKIN MODIFICATION

Specification
2024-T3 clad 1 Modification Skin (a) (h)
sheet, 96 x 54 x
0.112 inches
2024-T3 clad 1 Splice Doubler A (a)
sheet, 54 x 9 x
0.080 inches
2024-T3 clad 1 Splice Doubler B (a)
sheet, 38 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler A (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler B (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler C (a)
sheet, 9 x 9 x
0.080 inches
2024-T3 clad 1 Spar Doubler D (a)
sheet, 9 x 9 x
0.080 inches

737-55-1096

Specification
2024-T3 clad 1 Filler A (a)
sheet, 6 x 9 x
0.040 inches
2024-T3 clad 1 Filler B (a)
sheet, 6 x 9 x
0.040 inches
2024-T3 clad 1 Filler C (a)
sheet, 6 x 9 x
0.040 inches
2024-T3 clad 1 Filler D (a)
sheet, 6 x 9 x
0.040 inches
BACC30BL6 24 Collar (b) (g)
BMS 10-79, TYPE 32 oz Primer (c)
3
BMS 5-95, TYPE 32 oz Sealant (c)
1, CLASS B
TYPE 2, CLASS A 32 oz Chemical Conversion Coating (d)
(a) Fabricate from 2024-T3 clad sheet in accordance with FIGURE 6.
(b) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners.
(c) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)
for supplier data.
(d) Refer to SOPM 20-43-03 for material sources.
(e) Use BACR15GF61D( ) for first oversize, if necessary. Use BACR15GF7D( ) for second
(f) Use BACB30NW6K( )X for first oversize, if necessary. Use BACB30NW6K( )Y for second

737-55-1096

Specification
(g) Use BACC30M6 for first oversize, if necessary. Use BACC30R6 for second oversize, if
necessary.
(h) The 2024-T3 clad sheet material for the modification skin can be purchased from the
company below:
AMI Metals Inc.
840 Industry Drive North, Suite D
Auburn, WA 98001
Cage Code: 3C3F7
Local: (253) 735-0181
Fax: (253) 735-0104
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
Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service
Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of
the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase
order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin number and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145

737-55-1096
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST

RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT)
AND PRICE INFORMATION
Purchase Data:
Tool Number Name Unit Price as of
the Original Issue
date of this Ser-
vice Bulletin (US
Dollars)
ST1000-A-8252-1 STANDARD TOOL - BUCKING 769
BAR
BAR
BAR
BAR
BAR
F. Special Tooling Necessary to do this Service Bulletin
As an option to purchasing the bucking bars, operators can manufacture their own bucking bars in
accordance with Boeing Tooling Drawing ST1000-A-8252. Refer to Paragraph 1.J.2., Data supplied
with this Service Bulletin for supplied drawings.
As an option to using the bucking bars listed below, operators may use/make any bucking bar that is
suitable.
Operators may find it beneficial to have 2 of each bucking bar available if both left and right stabilizers
are being modified at the same time.
To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.
Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be
necessary. Examine operator tool supply to make sure all necessary tools are available.
Tool Number Name

ST1000-A-8252-1 STANDARD TOOL - BUCKING
BAR
BAR
BAR
BAR

737-55-1096
Tool Number Name

BAR

737-55-1096
BLANK PAGE

737-55-1096
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. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
4. 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 limits to tighten nuts and bolts are in SRM Chapter 51
5. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
6. 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.
7. 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.
8. 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.

737-55-1096
9. 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.
10. Refer to Appendix A for the recommended fastener installation sequence.
11. 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.
12. 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.
13. 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.
14. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
15. Some Boeing parts are supplied in a temporary configuration. Those parts are
identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is
permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'
(dash) part number. Boeing Drawing 005W0900 contains more data.
16. Shaded areas in Figures are to separate the non-critical and non-authoritative
information from the critical and authoritative information.
17. Long bucking bars can make rivet installation easier. Refer to Boeing Tooling drawing
ST1000-A-8252 for examples of long bucking bars. Refer to Paragraph 1.J.2., Data
supplied with this Service Bulletin. Operators may find it beneficial to have 2 of each
bucking bar available if both left and right stabilizers are being modified at the same
time. As an option to using the ST1000-A-8252 bucking bars, operators may use/make
any bucking bar that is suitable.
18. The instructions given in the work instructions are for on-airplane modification of the
horizontal stabilizer lower skin however the modification can also be installed with
the horizontal stabilizer removed from the airplane. For horizontal stabilizer removal
and installation, refer to 737-600/700/800/900 AMM 27-41-11 as an accepted
procedure.
19. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
20. Work Package 1 and Work Package 2 do not need to be done at the same time.
B. WORK INSTRUCTIONS
1. WORK PACKAGE 1: LEFT SIDE HORIZONTAL STABILIZER - LOWER SKIN MODIFICATION

737-55-1096
NOTE: If there is an existing repair installed common to the horizontal stabilizer upper or lower
skin outside of the modification area that is not within SRM limits, in accordance with
737-600 SRM 55-10-01, 737-700 SRM 55-10-01, 737-700CONV SRM 55-10-01,
737-700IGW (BBJ) SRM 55-10-01, 737-800 SRM 55-10-01, 737-900 SRM 55-10-01,
737-900ER SRM 55-10-01, contact Boeing for instructions and do the work instructed
by Boeing.
a. Remove and keep the left side horizontal stabilizer leading edge panel 331B. Refer to
737-600/700/800/900 AMM 27-41-21 as an accepted procedure.
b. Remove and keep the left side horizontal stabilizer front spar access panel 331BZ. Refer to
737-600/700/800/900 AMM 06-42-00.
c. Remove and keep the left side horizontal stabilizer trailing edge panels 333BB, 333CB and
333DB. Refer to 737-600/700/800/900 AMM 06-42-00.
d. Jack and shore the airplane as follows:
(1) Jack the airplane with jacks at Primary Jacking Point A, Primary Jacking Point B, Primary
Jacking Point C, and Auxiliary Jacking Point D. Refer to 737-600/700/800/900 AMM
07-11-01 as an accepted procedure.
(2) Install a Support, A-Frame Type Support Jig at the left side horizontal stabilizer, STAB
STA 193.9. Refer to 737-600 SRM 51-50-02, 737-700 SRM 51-50-02, 737-700CONV
SRM 51-50-02, 737-700IGW (BBJ) SRM 51-50-02, 737-800 SRM 51-50-02, 737-900
SRM 51-50-02 or 737-900ER SRM 51-50-02, Figure 10, Detail View A or Detail View B
or equivalent for an acceptable type support.
(3) Install a Support, A-Frame Type Support Jig at the right side horizontal stabilizer, STAB
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.
CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. WHEN THE FASTENERS
ARE REMOVED, USE CARE SO THE RIB FLANGE IS NOT DAMAGED. THE RIB
FLANGE CAN BE DAMAGED IF THE FASTENER TAIL IS PUNCHED THROUGH
WITHOUT ANY SUPPORT BEHIND THE RIB FLANGE. IF THE RIB FLANGE IS
DAMAGED, IT MAY BE NECESSARY TO REPLACE THE DAMAGED RIB.
e. Cut and remove the lower skin in accordance with FIGURE 1.
NOTE: Keep the removed skin so it can be used to locate fastener holes and drain holes in
the new skin.
f. Do a detailed inspection of the spar chords, ribs and rib vertical stiffeners common to front
and rear spars for cracks in the area common to the removed skin in accordance with FIGURE
2.

737-55-1096
(1) If any cracking is found in the rib vertical stiffeners between STAB STA 92.70 and 129.50,
install a repair in accordance 737-600 SRM 55-10-09 REPAIR 4, 737-700 SRM 55-10-09
REPAIR 4, 737-700CONV SRM 55-10-09 REPAIR 4, 737-700IGW (BBJ) SRM 55-10-09
REPAIR 4, 737-800 SRM 55-10-09 REPAIR 4, 737-900 SRM 55-10-09 REPAIR 4, or
737-900ER SRM 55-10-09 REPAIR 4.
(2) If any cracking is found in the spar chords or ribs within the inspection area or in the rib
vertical stiffeners between STAB STA 138.70 and 175.50, contact Boeing for repair
instructions and do the work instructed by Boeing.
CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. MAKE SURE THE LOWER
SKIN IS SUPPORTED AS THE FASTENERS ARE INSTALLED TO PREVENT
DAMAGE TO THE RIBS. IF THE RIB FLANGE IS DAMAGED , IT MAY BE
NECESSARY TO REPLACE THE DAMAGED RIB.
CAUTION: CARE MUST BE TAKEN TO INSTALL THE MODIFICATION SKIN CORRECTLY

WITH THE FASTENERS INSTALLED IN THE CORRECT SEQUENCE. IF
FASTENERS ARE INSTALLED INCORRECTLY, DAMAGE TO THE RIBS AND
SPARS CAN OCCUR AND THE SKIN COULD BECOME LOOSE.
g. Make and install the new left side horizontal stabilizer lower skin in accordance with FIGURE
3.
NOTE: There are access holes in the stabilizer front spar. Use these holes to make sure
fasteners are installed correctly.
h. Remove the A-Frame Type Support Jig at the right side horizontal stabilizer, STAB STA 193.9.
Refer to 737-600 SRM 51-50-02, 737-700 SRM 51-50-02, 737-700CONV SRM 51-50-02,
737-700IGW (BBJ) SRM 51-50-02, 737-800 SRM 51-50-02, 737-900 SRM 51-50-02 or
737-900ER SRM 51-50-02 as an accepted procedure.
i. Remove the A-Frame Type Support Jig at the left side horizontal stabilizer, STAB STA 193.9.
j. Remove the jacks at Primary Jacking Point A, Primary Jacking Point B, Primary Jacking Point
C, and Auxiliary Jacking Point D. Refer to 737-600/700/800/900 AMM 07-11-01 as an accepted
procedure.
k. Install the left side horizontal stabilizer front spar access panel 331BZ. Refer to
737-600/700/800/900 AMM 06-42-00.
l. Install the left side horizontal stabilizer leading edge panel 331B. Refer to 737-600/700/800/900
AMM 27-41-21 as an accepted procedure.
m. Install the left side horizontal stabilizer trailing edge panels 333BB, 333CB and 333DB. Refer
to 737-600/700/800/900 AMM 06-42-00.
n. Make sure the aerodynamic smoothness is within the limits in accordance with 737-600 SRM
51-10-01, 737-700 SRM 51-10-01, 737-700CONV SRM 51-10-01, 737-700IGW (BBJ) SRM
51-10-01, 737-800 SRM 51-10-01, 737-900 SRM 51-10-01 or 737-900ER SRM 51-10-01.

737-55-1096
o. Do the Elevator Power-Off Flight Test. Refer to 737-600/700/800/900 AMM 27-31-00 as an

accepted procedure.
p. Put the airplane back to a serviceable condition.
2. WORK PACKAGE 2: RIGHT SIDE HORIZONTAL STABILIZER - LOWER SKIN MODIFICATION
NOTE: If there is an existing repair installed common to the horizontal stabilizer upper or lower
skin outside of the modification area that is not within SRM limits, in accordance with
737-600 SRM 55-10-01, 737-700 SRM 55-10-01, 737-700CONV SRM 55-10-01,
737-700IGW (BBJ) SRM 55-10-01, 737-800 SRM 55-10-01, 737-900 SRM 55-10-01,
737-900ER SRM 55-10-01, contact Boeing for instructions and do the work instructed
by Boeing.
a. Remove and keep the right side horizontal stabilizer leading edge panel 341B. Refer to
b. Remove and keep the right side horizontal stabilizer front spar access panel 341BZ. Refer to
737-600/700/800/900 AMM 06-42-00.
c. Remove and keep the right side horizontal stabilizer trailing edge panels 343BB, 343CB and
343DB. Refer to 737-600/700/800/900 AMM 06-42-00.
d. Jack and shore the airplane as follows:
(1) Jack the airplane with jacks at Primary Jacking Point A, Primary Jacking Point B, Primary
Jacking Point C, and Auxiliary Jacking Point D. Refer to 737-600/700/800/900 AMM
07-11-01 as an accepted procedure.
(2) Install a Support, A-Frame Type Support Jig at the right side horizontal stabilizer, STAB
(3) Install a Support, A-Frame Type Support Jig at the left side horizontal stabilizer, STAB
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.
CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. WHEN THE FASTENERS
ARE REMOVED, USE CARE SO THE RIB FLANGE IS NOT DAMAGED. THE RIB
FLANGE CAN BE DAMAGED IF THE FASTENER TAIL IS PUNCHED THROUGH
WITHOUT ANY SUPPORT BEHIND THE RIB FLANGE. IF THE RIB FLANGE IS
DAMAGED, IT MAY BE NECESSARY TO REPLACE THE DAMAGED RIB.
e. Cut and remove the lower skin in accordance with FIGURE 4.

737-55-1096
NOTE: Keep the removed skin so it can be used to locate fastener holes and drain holes in
the new skin.
f. Do a detailed inspection of the spar chords, ribs and rib vertical stiffeners common to the front
and rear spars for cracks in the area common to the removed skin in accordance with FIGURE
5.
(1) If any cracking is found in the rib vertical stiffeners between STAB STA 92.70 and 129.50,
install a repair in accordance 737-600 SRM 55-10-09 REPAIR 4, 737-700 SRM 55-10-09
REPAIR 4, 737-700CONV SRM 55-10-09 REPAIR 4, 737-700IGW (BBJ) SRM 55-10-09
REPAIR 4, 737-800 SRM 55-10-09 REPAIR 4, 737-900 SRM 55-10-09 REPAIR 4, or
737-900ER SRM 55-10-09 REPAIR 4.
(2) If any cracking is found in the spar chords or ribs within the inspection area or in the rib
vertical stiffeners between STAB STA 138.70 and 175.50, contact Boeing for repair
CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. MAKE SURE THE LOWER
SKIN IS SUPPORTED AS THE FASTENERS ARE INSTALLED TO PREVENT
DAMAGE TO THE RIBS. IF THE RIB FLANGE IS DAMAGED, IT MAY BE
NECESSARY TO REPLACE THE DAMAGED RIB.
CAUTION: CARE MUST BE TAKEN TO INSTALL THE MODIFICATION SKIN CORRECTLY

WITH THE FASTENERS INSTALLED IN THE CORRECT SEQUENCE. IF
FASTENERS ARE INSTALLED INCORRECTLY, DAMAGE TO THE RIBS AND
SPARS CAN OCCUR AND THE SKIN COULD BECOME LOOSE.
g. Make and install the new right side horizontal stabilizer lower skin in accordance with FIGURE
6.
NOTE: There are access holes in the stabilizer front spar. Use these holes to make sure
fasteners are installed correctly.
h. Remove the A-Frame Type Support Jig at the left side horizontal stabilizer, STAB STA 193.9.
i. Remove the A-Frame Type Support Jig at the right side horizontal stabilizer, STAB STA 193.9.
j. Remove the jacks at Primary Jacking Point A, Primary Jacking Point B, Primary Jacking Point
C, and Auxiliary Jacking Point D. Refer to 737-600/700/800/900 AMM 07-11-01 as an accepted
procedure.
k. Install the right side horizontal stabilizer front spar access panel 341BZ. Refer to
737-600/700/800/900 AMM 06-42-00.
l. Install the right side horizontal stabilizer leading edge panel 341B. Refer to

737-55-1096
m. Install the right side horizontal stabilizer trailing edge panels 343BB, 343CB and 343DB. Refer
to 737-600/700/800/900 AMM 06-42-00.
n. Make sure the aerodynamic smoothness is within the limits in accordance with 737-600 SRM
51-10-01, 737-700 SRM 51-10-01, 737-700CONV SRM 51-10-01, 737-700IGW (BBJ) SRM
51-10-01, 737-800 SRM 51-10-01, 737-900 SRM 51-10-01 or 737-900ER SRM 51-10-01.
o. Do the Elevator Power-Off Flight Test. Refer to 737-600/700/800/900 AMM 27-31-00 as an

accepted procedure.
p. Put the airplane back to a serviceable condition.
3. POST MODIFICATION INSPECTIONS
a. Do detailed and eddy current inspections of the left side horizontal stabilizer lower skin
modification for cracks in accordance with FIGURE 7 at the times given in Paragraph 1.E.,
Compliance.
(1) If any crack is found in the existing skin, modification skin, splice doublers, spar lower
chords or spar doublers, contact Boeing for repair instructions and do the work instructed
by Boeing.
b. Do detailed and eddy current inspections of the right side horizontal stabilizer lower skin for
cracks in accordance with FIGURE 8 at the times given in Paragraph 1.E., Compliance.
(1) If any crack is found in the existing skin, modification skin, splice doublers, spar lower
chords or spar doublers, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do eddy current inspections of the left side horizontal stabilizer front spar upper chord as
follows:
(1) Remove the left side horizontal stabilizer leading edge panel 331B. Refer to
(2) Remove the left side horizontal stabilizer front spar access panels 331BZ, 331CZ and
331DZ. Refer to 737-600/700/800/900 AMM 06-42-00.
NOTE: Removal of the horizontal stabilizer front spar access panels is only required for
the front spar upper chord web flange inspection between STAB STA 175.5 and
STAB STA 258.28.
(3) Do eddy current inspections of the left side horizontal stabilizer front spar upper chord
for cracks in accordance with FIGURE 9 at the times given in Paragraph 1.E., Compliance.
(a) If any crack is found in the front spar upper chord, remove the crack damage in
accordance with 737-600 SRM 55-10-10, 737-700 SRM 55-10-10, 737-700CONV
SRM 55-10-10 or 737-900ER SRM 55-10-10. Alternatively, contact Boeing for repair
d. Do eddy current inspections of the right side horizontal stabilizer front spar upper chord as
follows:

737-55-1096
(1) Remove the right side horizontal stabilizer leading edge panel 341B. Refer to
(2) Remove the right side horizontal stabilizer front spar access panels 341BZ, 341CZ and
341DZ. Refer to 737-600/700/800/900 AMM 06-42-00.
NOTE: Removal of the horizontal stabilizer front spar access panels is only required for
the front spar upper chord web flange inspection between STAB STA 175.5 and
STAB STA 258.28.
(3) Do eddy current inspections of the right side horizontal stabilizer front spar upper chord
for cracks in accordance with FIGURE 10 at the times given in Paragraph 1.E.,
Compliance.
(a) If any crack is found in the front spar upper chord, remove the crack damage in
accordance with 737-600 SRM 55-10-10, 737-700 SRM 55-10-10, 737-700CONV
SRM 55-10-10 or 737-900ER SRM 55-10-10. Alternatively, contact Boeing for repair
e. If removed, install the left and right side horizontal stabilizer front spar access panels 331BZ,
331CZ, 331DZ, 341BZ, 341CZ and 341DZ. Refer to 737-600/700/800/900 AMM 06-42-00.
f. If removed, install the left and right side horizontal stabilizer leading edge panels 331B and
341B. Refer to 737-600/700/800/900 AMM 27-41-21 as an accepted procedure.
g. Put the airplane back to a serviceable condition.
h. Repeat the Paragraph 3.B., Work Instructions, Step 3 Post Modification Inspections at the
times given in Paragraph 1.E., Compliance.

737-55-1096
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 this figure.
Step Task Name Identification Qty More Data

CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. WHEN THE FASTENERS ARE REMOVED,
USE CARE SO THE RIB FLANGE IS NOT DAMAGED. THE RIB FLANGE CAN BE DAMAGED
IF THE FASTENER TAIL IS PUNCHED THROUGH WITHOUT ANY SUPPORT BEHIND THE
RIB FLANGE. IF THE RIB FLANGE IS DAMAGED, IT COULD BE NECESSARY TO REPLACE
THE DAMAGED RIB.
1 Remove Fastener - 1184 (d)

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 Cut Skin - - (a)

3 Cut Skin - - (b)
FIGURE 1: LEFT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL

(SHEET 1 OF 2)
737-55-1096

4 Remove Skin - - (c)
(a) Cut the skin as shown. On the skin inboard of the cut, maintain a minimum radius of 0.50 inches. Maintain
a minimum 2D edge margin at the spar chord fasteners.
(b) Cut the skin as shown. On the skin outboard of the cut, maintain a minimum radius of 0.50 inches. Maintain
(c) Keep the removed skin to locate fastener and drain holes in the modification skin.
(d) The Quantity listed is for reference only.
FIGURE 1: LEFT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL

(SHEET 2 OF 2)
737-55-1096

1 Inspect Front Spar Lower - - (a)
Chord
Inspect Rear Spar Lower Chord - - (a)
Inspect Rib - 10 (a)
Inspect Rib Vertical Stiffeners - - (a)
(a) Do a detailed inspection of the front and rear spar lower chords, ribs and rib vertical stiffeners common
to the front and rear spars for cracks in the area common to the removed skin.
FIGURE 2: LEFT SIDE HORIZONTAL STABILIZER - INTERNAL STRUCTURE INSPECTION

(SHEET 1 OF 1)
737-55-1096
FIGURE 3: LEFT SIDE HORIZONTAL STABILIZER - MODIFICATION SKIN INSTALLATION

(SHEET 1 OF 6)
737-55-1096

1 Make Modification Skin - 1 Refer to fastener ta-
ble for hole sizes. (a)
(b) (c) (d) (e) (f) (g)
(u)
Make Splice Doubler A - 1 Refer to fastener ta-
ble for hole sizes. (b)
(c) (d) (e) (f) (g) (h)
(t)
Make Splice Doubler B - 1 Refer to fastener ta-
(c) (d) (e) (f) (g) (h)
(t)
Make Spar Doubler A - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler B - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler C - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler D - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Filler A - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler B - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler C - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler D - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)

(SHEET 2 OF 6)
737-55-1096

2 Apply Chemical Conversion TYPE 2, CLASS A - (k)
Coating
Apply Primer BMS 10-79, TYPE 3 - (l)
3 Make Countersink Repair - 50 (m)
Washer
4 Install (New) Countersink Repair - 50 (m)
Washer
5 Install (New) Splice Doubler A - 1 Refer to fastener ta-
ble. (n) (r) (t)
Install (New) Splice Doubler B - 1 Refer to fastener ta-
ble. (n) (r) (t)
CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. MAKE SURE THE LOWER SKIN IS
SUPPORTED AS THE FASTENERS ARE INSTALLED TO PREVENT DAMAGE TO THE RIBS.
IF THE RIB FLANGE IS DAMAGED, IT COULD BE NECESSARY TO REPLACE THE DAMAGED
RIB.
CAUTION: CARE MUST BE TAKEN TO INSTALL THE MODIFICATION SKIN CORRECTLY WITH THE
FASTENERS INSTALLED IN THE CORRECT SEQUENCE. IF FASTENERS ARE INSTALLED
INCORRECTLY, DAMAGE TO THE RIBS AND SPARS CAN OCCUR AND THE SKIN COULD
BECOME LOOSE.
6 Install (New) Modification Skin - 1 Refer to fastener ta-

ble. (n) (q) (s)
Install (New) Filler A - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler A - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler B - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler B - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler C - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler C - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler D - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler D - 1 Refer to fastener ta-
ble. (n) (q)

(SHEET 3 OF 6)
737-55-1096

7 Apply Sealant BMS 5-95 - (o)
8 Apply External Finish - - (p)
(a) Make from 2024-T3 clad sheet, 0.112 inches thick. Make the modification skin the same size as the skin
that was removed in FIGURE 1. Use the kept skin to backdrill the fastener holes common to the ribs, spar
chords and the drain holes. Refer to fastener code table.
(b) Maintain a minimum of 2D edge margin at all fastener locations. Maintain a 4D to 6D spacing between
rows of fasteners common to the splice doublers. Maintain a maximum gap of 0.090 inches between the
existing skin and the modification skin.
(c) Do not drill any holes on a chem-mill radius.
(d) Keep the drainage holes in their original position. Maintain the correct fastener spacing and edge margin
around the drainage holes.
(e) Make sure there are no nicks, scratches, burrs or sharp edges on the modification parts or the skin.
(f) Keep a minimum radius of 0.50 inches at all corners.
(g) Make sure all cut surfaces have a surface finish of 63 Ra or better.
(h) Make from 2024-T3 clad sheet 0.080 inches thick. Make the contour of each splice doubler the same as
an adjacent rib, inboard or outboard.
(i) Make from 2024-T3 clad sheet 0.080 inches thick.
(j) Make from 2024-T3 clad sheet 0.040 inches thick. The filler is installed between the existing skin and the
spar doubler to account for the difference in thickness between the existing skin and the modification skin.
(k) Apply to all bare aluminum surfaces of the existing skin, modification skin, splice doublers, spar doublers
and fillers. Refer to SOPM 20-43-03 as an accepted procedure.
(l) Apply to all bare aluminum surfaces of the existing skin, modification skin, splice doublers, spar doublers
(m) Refer to 737-600 SRM 51-40-08, 737-700 SRM 51-40-08, 737-700CONV SRM 51-40-08, 737-700IGW
(BBJ) SRM 51-40-08, 737-800 SRM 51-40-08, 737-900 SRM 51-40-08 or 737-900ER SRM 51-40-08 as
an accepted procedure.
(n) Install with BMS 5-95 between the mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.
(o) Fillet seal around all external modification parts and gap seal between the existing skin and modification
skin. Refer to SOPM 20-50-19 as an accepted procedure.
(p) Apply as necessary to the external surface of the modification area to match the adjacent structure. Refer
to 737-600/700/800/900 AMM 51-21-00 as an accepted procedure.
(q) Refer to APPENDIX A for the recommended fastener installation sequence.
(r) Boeing recommends that only fasteners common to the existing skin in the forward half of the splice are
installed at this point. Do not install any fasteners common to the spar doublers. Access to install the spar
doublers common to the rear spar is improved if the fasteners common to the existing skin in the aft half
of the splice are not installed at this time. The remaining fasteners can be installed during skin installation.
(s) Maintain a minimum of 1.5D edge margin for fastener locations common to the ribs.

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(t) The quantity of fastener location is dependant on the fastener spacing common to the splice doublers.
(u) Chamfer edge all around external periphery except under Spar Doublers. Refer to View H-H on sheet 5.
(v) Chamfer edge of Spar Doublers. Refer to View D sheet 5
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. The QTY numbers shown below are the
number of fasteners necessary for this figure.
Code Name Identification Qty Hole Dia More Data

A Rivet BACR15GF6D6 897 0.190 - 0.196 (a) (f) (g)
Rivet BACR15GF6D7 363 0.190 - 0.196 (a) (f) (g)
Rivet BACR15GF6D9 16 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D10 4 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D11 4 0.190 - 0.196 (a) (g)
B Rivet BACR15GF6D8 117 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D9 39 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D10 142 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D11 26 0.190 - 0.196 (a) (g)
Rivet BACR15GF61D( ) - 0.205 - 0.209 1st Oversize. (a) (b) (c) (g)
Rivet BACR15GF7D( ) - 0.225 - 0.231 2nd Oversize. (a) (b) (c)
(g)

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C Bolt BACB30VU6K7 4 0.187 - 0.190 (d) (g)
Bolt BACB30VU6K8 16 0.187 - 0.190 (d) (e) (g)
Bolt BACB30VU6K9 4 0.187 - 0.190 (d) (e) (g)
Collar BACC30BL6 24 -
Bolt BACB30NW6K( )X - 0.200 - 0.203 1st Oversize. (b) (c) (d) (g)
Collar BACC30M6 - - 1st Oversize.
Bolt BACB30NW6K( )Y - 0.216 - 0.219 2nd Oversize. (b) (c) (d)
(g)
Collar BACC30R6 - - 2nd Oversize.
D Drainage Hole - 10 0.300 - 0.385
(a) Overdrive all rivets to 1.4 times diameter.
(b) Use oversize fasteners if the hole diameter is not within the limits given. Make sure a minimum 2D edge
margin can be maintained.
(c) Fastener length determined on installation.
(d) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 as an accepted procedure.
(e) Install a washer under the collar if necessary.
(f) The final quantity of fasteners is dependant on the fastener spacing chosen common to the splice doublers
and may differ from that shown in the fastener table or the drawing.
(g) Refer to APPENDIX A for the recommended fastener installation sequence.

(SHEET 6 OF 6)
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CAUTION: THE RIB FLANGE IS A THIN MACHINED SECTION. WHEN THE FASTENERS ARE REMOVED,
USE CARE SO THE RIB FLANGE IS NOT DAMAGED. THE RIB FLANGE CAN BE DAMAGED
IF THE FASTENER TAIL IS PUNCHED THROUGH WITHOUT ANY SUPPORT BEHIND THE
RIB FLANGE. IF THE RIB FLANGE IS DAMAGED, IT COULD BE NECESSARY TO REPLACE
THE DAMAGED RIB.
1 Remove Fastener - 1184 (d)

2 Cut Skin - - (a)

3 Cut Skin - - (b)
FIGURE 4: RIGHT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL

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4 Remove Skin - - (c)
(a) Cut the skin as shown. On the skin inboard of the cut, maintain a minimum radius of 0.50 inches. Maintain
(b) Cut the skin as shown. On the skin outboard of the cut, maintain a minimum radius of 0.50 inches. Maintain
(c) Keep the removed skin to locate fastener and drain holes in the modification skin.
(d) The quantity listed is for reference only.
FIGURE 4: RIGHT SIDE HORIZONTAL STABILIZER LOWER SKIN - REMOVAL

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1 Inspect Front Spar Lower - - (a)
Chord
Inspect Rear Spar Lower Chord - - (a)
Inspect Rib - 10 (a)
Inspect Rib Vertical Stiffeners - - (a)
(a) Do a detailed inspection of the front and rear spar lower chords, ribs and rib vertical stiffeners common
to the front and rear spars for cracks in the area common to the removed skin.
FIGURE 5: RIGHT SIDE HORIZONTAL STABILIZER - INTERNAL STRUCTURE INSPECTION

(SHEET 1 OF 1)
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FIGURE 6: RIGHT SIDE HORIZONTAL STABILIZER - MODIFICATION SKIN INSTALLATION

(SHEET 1 OF 6)
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1 Make Modification Skin - 1 Refer to fastener ta-
ble for hole sizes. (a)
(b) (c) (d) (e) (f) (g)
(u)
Make Splice Doubler A - 1 Refer to fastener ta-
(c) (d) (e) (f) (g) (h)
(t)
Make Splice Doubler B - 1 Refer to fastener ta-
(c) (d) (e) (f) (g) (h)
(t)
Make Spar Doubler A - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler B - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler C - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Spar Doubler D - 1 Refer to fastener ta-
(c) (e) (f) (g) (i) (v)
Make Filler A - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler B - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler C - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)
Make Filler D - 1 Refer to fastener ta-
(c) (e) (f) (g) (j)

(SHEET 2 OF 6)
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2 Apply Chemical Conversion TYPE 2, CLASS A - (k)
Coating
Apply Primer BMS 10-79, TYPE 3 - (l)
3 Make Countersink Repair - 50 (m)
Washer
4 Install (New) Countersink Repair - 50 (m)
Washer
5 Install (New) Splice Doubler A - 1 Refer to fastener ta-
ble. (n) (r) (t)
Install (New) Splice Doubler B - 1 Refer to fastener ta-
ble. (n) (r) (t)
IF THE RIB FLANGE IS DAMAGED , IT COULD BE NECESSARY TO REPLACE THE DAMAGED
RIB.
FASTENERS INSTALLED IN THE CORRECT SEQUENCE. IF FASTENERS ARE INSTALLED
INCORRECTLY, DAMAGE TO THE RIBS AND SPARS CAN OCCUR AND THE SKIN MAY
BECOME LOOSE.
6 Install (New) Modification Skin - 1 Refer to fastener ta-

ble. (n) (q) (s)
Install (New) Filler A - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler A - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler B - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler B - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler C - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler C - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Filler D - 1 Refer to fastener ta-
ble. (n) (q)
Install (New) Spar Doubler D - 1 Refer to fastener ta-
ble. (n) (q)

(SHEET 3 OF 6)
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7 Apply Sealant BMS 5-95 - (o)
8 Apply External Finish - - (p)
(a) Make from 2024-T3 clad sheet, 0.112 inches thick. Make the modification skin the same size as the skin
that was removed in FIGURE 1. Use the kept skin to backdrill the fastener holes common to the ribs, spar
chords and the drain holes. Refer to fastener code table.
(b) Maintain a minimum of 2D edge margin at all fastener locations. Maintain a 4D to 6D spacing between
rows of fasteners common to the splice doublers. Maintain a maximum gap of 0.090 inches between the
existing skin and the modification skin.
(c) Do not drill any holes on a chem-mill radius.
(d) Keep the drainage holes in their original position. Maintain the correct fastener spacing and edge margin
around the drainage holes.
(e) Make sure there are no nicks, scratches, burrs or sharp edges on the modification parts or the skin.
(f) Keep a minimum radius of 0.50 inches at all corners.
(g) Make sure all cut surfaces have a surface finish of 63 Ra or better.
(h) Make from 2024-T3 clad sheet 0.080 inches thick. Make the contour of each splice doubler the same as
an adjacent rib, inboard or outboard.
(i) Make from 2024-T3 clad sheet 0.080 inches thick.
(j) Make from 2024-T3 clad sheet 0.040 inches thick. The filler is installed between the existing skin and the
spar doubler to account for the difference in thickness between the existing skin and the modification skin.
(k) Apply to all bare aluminum surfaces of the existing skin, modification skin, splice doublers, spar doublers
(l) Apply to all bare aluminum surfaces of the existing skin, modification skin, splice doublers, spar doublers
(m) Refer to 737-600 SRM 51-40-08, 737-700 SRM 51-40-08, 737-700CONV SRM 51-40-08, 737-700IGW
(BBJ) SRM 51-40-08, 737-800 SRM 51-40-08, 737-900 SRM 51-40-08 or 737-900ER SRM 51-40-08 as
an accepted procedure.
(n) Install with BMS 5-95 between the mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.
(o) Fillet seal around all external modification parts and gap seal between the existing and modification skin.
Refer to SOPM 20-50-19 as an accepted procedure.
(p) Apply as necessary to the external surface of the modification area to match the adjacent structure. Refer
to 737-600/700/800/900 AMM 51-21-00 as an accepted procedure.
(q) Refer to APPENDIX A for the recommended fastener installation sequence.
(r) Boeing recommends that only fasteners common to the existing skin in the forward half of the splice are
installed at this point. Do not install any fasteners common to the spar doublers. Access to install the spar
doublers common to the rear spar is improved if the fasteners common to the existing skin in the aft half
of the splice are not installed at this time. The remaining fasteners can be installed during skin installation.
(s) Maintain a minimum of 1.5D edge margin for fastener locations common to the ribs.

(SHEET 4 OF 6)
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(t) The quantity of fastener location is dependant on the fastener spacing common to the splice doublers.
(u) Chamfer edge all around external periphery except under Spar Doublers. Refer to View H-H on sheet 7.
(v) Chamfer edge of Spar Doublers. Refer to View H-H on sheet 7.
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. The QTY numbers shown below are the
number of fasteners necessary for this figure.

A Rivet BACR15GF6D6 897 0.190 - 0.196 (a) (f) (g)
Rivet BACR15GF6D9 16 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D10 4 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D11 4 0.190 - 0.196 (a) (g)
B Rivet BACR15GF6D8 117 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D9 39 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D10 142 0.190 - 0.196 (a) (g)
Rivet BACR15GF6D11 26 0.190 - 0.196 (a) (g)
Rivet BACR15GF61D( ) - 0.205 - 0.209 1st Oversize. (a) (b) (c) (g)
Rivet BACR15GF7D( ) - 0.225 - 0.231 2nd Oversize. (a) (b) (c)
(g)

(SHEET 5 OF 6)
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C Bolt BACB30VU6K7 4 0.187 - 0.190 (d) (g)
Bolt BACB30VU6K8 16 0.187 - 0.190 (d) (e) (g)
Bolt BACB30VU6K9 4 0.187 - 0.190 (d) (e) (g)
Collar BACC30BL6 24 -
Bolt BACB30NW6K( )X - 0.200 - 0.203 1st Oversize. (b) (c) (d) (g)
Collar BACC30M6 - - 1st Oversize.
Bolt BACB30NW6K( )Y - 0.216 - 0.219 2nd Oversize. (b) (c) (d)
(g)
Collar BACC30R6 - - 2nd Oversize.
D Drainage Hole - 10 0.300 - 0.385
(a) Overdrive all rivets to 1.4 times diameter.
(b) Use oversize fasteners if the hole diameter is not within the limits given. Make sure a minimum 2D edge
margin can be maintained.
(c) Fastener length determined on installation.
(d) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 as an accepted procedure.
(e) Install a washer under the collar if necessary.
(f) The final quantity of fasteners is dependant on the fastener spacing chosen common to the splice doublers
and may differ from that shown in the fastener table or the drawing.
(g) Refer to APPENDIX A for the recommended fastener installation sequence.

(SHEET 6 OF 6)
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INSPECTION
(SHEET 1 OF 7)
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INSPECTION
(SHEET 2 OF 7)
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INSPECTION
(SHEET 3 OF 7)
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INSPECTION
(SHEET 4 OF 7)
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INSPECTION
(SHEET 5 OF 7)
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1 Inspect Modification Skin - - (a)
Inspect Existing Skin - - (a)
2 Inspect Spar Doubler C - 1 (b)
3 Inspect Existing Skin - - (c) (f)
Inspect Modification Skin - - (c) (f)
4 Inspect Spar Doubler A - 1 (b)
6 Inspect Splice Doubler A - 1 (d) (g)
7 Inspect Front Spar Lower - - (e) (h)
Chord
8 Inspect Rear Spar Lower Chord - - (e) (h)
9 Inspect Spar Doubler D - 1 (b)
11 Inspect Spar Doubler B - 1 (b)
13 Inspect Splice Doubler B - 1 (d) (g)
Chord
(a) Do a detailed inspection of the modification skin and existing skin for cracks between Stabilizer Station
(STAB STA) 83.50 and 184.70
(b) Do a detailed inspection of the spar doubler for cracks.
(c) Do an eddy current inspection of the modification skin and existing skin in the area covered by the spar
doubler for cracks in accordance with 737 NDT Manual Part 6, 51-00-26 or 737 NDT Manual Part 6, 53-
30-00 Figure 5.
(d) Do an eddy current inspection of the splice doubler for cracks in accordance with 737 NDT Manual Part
6, 51-00-26 or 737 NDT Manual Part 6, 53-30-00 Figure 5.
(e) Do an eddy current inspection of the spar lower chord in the area covered by the spar doubler for cracks
in accordance with 737 NDT Manual Part 6, 51-00-26 or 737 NDT Manual Part 6, 53-30-00 Figure 5.
INSPECTION
(SHEET 6 OF 7)
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(f) The modification skin thickness is 0.112 inches. The existing skin thickness is 0.071 inches. The total
thickness of parts above the modification skin (spar doubler only) is 0.080 inches. The total thickness of
parts above the existing skin (spar doubler and filler) is 0.120 inches.
(g) The splice doubler thickness is 0.080 inches. The modification skin thickness is 0.112 inches. The existing
skin thickness is 0.071 inches. The total thickness of parts above the splice doubler common to the spar
doubler is 0.191 to 0.192 inches.
(h) The front spar lower chord below spar doubler C has a variable thickness of between 0.153 to 0.190
inches. The front spar lower chord below spar doubler D has a thickness of 0.1375 inches. The rear spar
lower chord below spar doubler A has a variable thickness of between 0.380 to 0.280 inches. The rear
spar lower chord below spar doubler B has a thickness of 0.250 inches. The total thickness of parts above
the spar lower chords is 0.191 to 0.192 inches.
INSPECTION
(SHEET 7 OF 7)
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FIGURE 8: RIGHT SIDE HORIZONTAL STABILIZER LOWER SKIN MODIFICATION - POST MODIFICATION
INSPECTION
(SHEET 1 OF 7)
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INSPECTION
(SHEET 2 OF 7)
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INSPECTION
(SHEET 3 OF 7)
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INSPECTION
(SHEET 4 OF 7)
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INSPECTION
(SHEET 5 OF 7)
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1 Inspect Modification Skin - - (a)
Inspect Existing Skin - - (a)
2 Inspect Spar Doubler C - 1 (b)
4 Inspect Spar Doubler A - 1 (b)
6 Inspect Splice Doubler A - 1 (d) (g)
Chord
9 Inspect Spar Doubler D - 1 (b)
11 Inspect Spar Doubler B - 1 (b)
13 Inspect Splice Doubler B - 1 (d) (g)
Chord
(a) Do a detailed inspection of the modification skin and existing skin for cracks between Stabilizer Station
(STAB STA) 83.50 and 184.70
(b) Do a detailed inspection of the spar doubler for cracks.
(c) Do an eddy current inspection of the modification skin and existing skin in the area covered by the spar
doubler for cracks in accordance with 737 NDT Manual Part 6, 51-00-26 or 737 NDT Manual Part 6, 53-
30-00 Figure 5.
(d) Do an eddy current inspection of the splice doubler for cracks in accordance with 737 NDT Manual Part
6, 51-00-26 or 737 NDT Manual Part 6, 53-30-00 Figure 5.
(e) Do an eddy current inspection of the spar lower chord in the area covered by the spar doubler for cracks
in accordance with 737 NDT Manual Part 6, 51-00-26 or 737 NDT Manual Part 6, 53-30-00 Figure 5.
INSPECTION
(SHEET 6 OF 7)
737-55-1096

(f) The modification skin thickness is 0.112 inches. The existing skin thickness is 0.071 inches. The total
thickness of parts above the modification skin (spar doubler only) is 0.080 inches. The total thickness of
parts above the existing skin (spar doubler and filler) is 0.120 inches.
(g) The splice doubler thickness is 0.080 inches. The modification skin thickness is 0.112 inches. The existing
skin thickness is 0.071 inches. The total thickness of parts above the splice doubler common to the spar
doubler is 0.191 to 0.192 inches.
(h) The front spar lower chord below spar doubler C has a variable thickness of between 0.153 to 0.190
inches. The front spar lower chord below spar doubler D has a thickness of 0.1375 inches. The rear spar
lower chord below spar doubler A has a variable thickness of between 0.380 to 0.280 inches. The rear
spar lower chord below spar doubler B has a thickness of 0.250 inches. The total thickness of parts above
the spar lower chords is 0.191 to 0.192 inches.
INSPECTION
(SHEET 7 OF 7)
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FIGURE 9: LEFT SIDE HORIZONTAL STABILIZER - FRONT SPAR UPPER CHORD - POST MODIFICATION
INSPECTION
(SHEET 1 OF 4)
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INSPECTION
(SHEET 2 OF 4)
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INSPECTION
(SHEET 3 OF 4)
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1 Inspect Front Spar Upper - - (a)
Chord Aft Flange
2 Inspect Front Spar Upper - - (b)
Chord Forward Flange
3 Inspect Front Spar Upper - - (c)
Chord Web Flange
4 Inspect Front Spar Upper - - (d)
Chord Web Flange
5 Inspect Front Spar Upper - - (e)
Chord Web Flange
(a) Do a low frequency eddy current (LFEC) inspection of the front spar upper chord aft flange from STAB
STA 66.50 to STAB Tip for cracks in accordance with 737 NDT Manual Part 6, 55-10-32. Do the inspection
from the horizontal stabilizer upper skin side.
(b) Do a high frequency eddy current (HFEC) inspection of the front spar upper chord forward flange from
STAB STA 66.50 to STAB Tip for cracks in accordance with 737 NDT Manual Part 6, 55-10-46. Do the
inspection from the leading edge upper skin side.
(c) Do a LFEC inspection of the front spar upper chord web flange from STAB STA 66.50 to STAB STA
175.50 and STAB STA 258.28 to STAB Tip for cracks in accordance with 737 NDT Manual Part 6, 55-
10-45. Do the inspection from the forward side of the front spar.
(d) Do a HFEC inspection of the front spar upper chord web flange from STAB STA 66.50 to STAB STA
10-47. Place probe on primed metal surface and use top edge of web as a guide. Do the inspection from
the forward side of the front spar.
(e) Do a HFEC inspection of the front spar upper chord web flange from STAB STA 175.50 to STAB STA
258.28 for cracks in accordance with 737 NDT Manual Part 6, 55-10-47. Place probe on primed metal
surface at hole of removed fasteners. Do the inspection from the forward side of the front spar.
INSPECTION
(SHEET 4 OF 4)
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FIGURE 10: RIGHT SIDE HORIZONTAL STABILIZER - FRONT SPAR UPPER CHORD - POST MODIFICATION
INSPECTION
(SHEET 1 OF 4)
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INSPECTION
(SHEET 2 OF 4)
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INSPECTION
(SHEET 3 OF 4)
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1 Inspect Front Spar Upper - - (a)
Chord Aft Flange
2 Inspect Front Spar Upper - - (b)
Chord Forward Flange
3 Inspect Front Spar Upper - - (c)
Chord Web Flange
4 Inspect Front Spar Upper - - (d)
Chord Web Flange
5 Inspect Front Spar Upper - - (e)
Chord Web Flange
(a) Do a low frequency eddy current (LFEC) inspection of the front spar upper chord aft flange from STAB
STA 66.50 to STAB Tip for cracks in accordance with 737 NDT Manual Part 6, 55-10-32. Do the inspection
from the horizontal stabilizer upper skin side.
(b) Do a high frequency eddy current (HFEC) inspection of the front spar upper chord forward flange from
STAB STA 66.50 to STAB Tip for cracks in accordance with 737 NDT Manual Part 6, 55-10-46. Do the
inspection from the leading edge upper skin side.
(c) Do a LFEC inspection of the front spar upper chord web flange from STAB STA 66.50 to STAB STA
10-45. Do the inspection from the forward side of the front spar.
(d) Do a HFEC inspection of the front spar upper chord web flange from STAB STA 66.50 to STAB STA
10-47. Place probe on primed metal surface and use top edge of web as a guide. Do the inspection from
the forward side of the front spar.
(e) Do a HFEC inspection of the front spar upper chord web flange from STAB STA 175.50 to STAB STA
258.28 for cracks in accordance with 737 NDT Manual Part 6, 55-10-47. Place probe on primed metal
surface at hole of removed fasteners. Do the inspection from the forward side of the front spar.
INSPECTION
(SHEET 4 OF 4)
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FASTENERS INSTALLED IN THE ORDER GIVEN. IF FASTENERS ARE INSTALLED
INCORRECTLY, DAMAGE TO THE RIBS AND SPARS CAN OCCUR AND THE SKIN MAY
BECOME LOOSE.
IF THE RIB FLANGE IS DAMAGED, IT COULD BE NECESSARY TO REPLACE THE DAMAGED
RIB.
1. Boeing recommends to install the fasteners in the sequence given below. Refer to the Fastener
Installation Sequence Illustration:
NOTE: Make sure there are always 4 rows of skin pins (temporary fasteners) installed forward of the
previously installed fastener.
NOTE: There could be more or less zones than shown in the illustration dependant on the fastener
spacing chosen.
– Install all the fasteners in the rear spar zone first, starting at the inboard end working outboard.
– Install 4 rows of skin pins (temporary fasteners) forward of the fasteners installed in the rear spar.
– Install all fasteners in Zone 1 starting at the inboard end working outboard.
– Install all fasteners in Zone 2 starting at the inboard end working outboard. Proceed to the next
zone forward and continue to install all fasteners in that zone starting at the inboard end working
outboard.
– Continue with method described above installing all fasteners in a zone, inboard to outboard, then
proceeding to the next zone forward until all fasteners are installed along the front spar.
APPENDIX A: FASTENER INSTALLATION SEQUENCE

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APPENDIX A: FASTENER INSTALLATION SEQUENCE

(SHEET 2 OF 2)
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The estimated penalty for the modification is 57lb Equivalent Operating Empty Weight. The fuel burn penalty
for these modifications is estimated at 690 US gallons of fuel per year.
The calculations are based on the following assumptions:
– The skin modification has been accomplished on both the left and right horizontal stabilizers.
– The modification skin has an 8 degree chamfer.
– The airplane accumulates 2,120 flight cycles per year.
– The airplane has a mission range of 500 nautical miles.
APPENDIX B: FUEL BURN PENALTY ANALYSIS

(SHEET 1 OF 1)
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Commercial

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Cracking and Modification

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Original Issue: March 22, 2013

Original Issue: March 22, 2013

Original Issue: March 22, 2013

Original Issue: March 22, 2013

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Cracking and Modification

Original Issue: March 22, 2013

Planning Data Affected Reference

ACTION (PRR 38275-153)

Work Package 1: Left Side Horizontal Stabilizer - Skin Modification

Work Package 2: Right Side Horizontal Stabilizer - Skin Modification

Original Issue: March 22, 2013

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Airplanes Total Task Hours Elapsed Hours

Operator Supplied Parts/Materials.

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

Original Issue: March 22, 2013

Original Issue: March 22, 2013

SUBJECT: STABILIZERS - Horizontal Stabilizer - Lower Skin Cracking and Modification

GROUP CONFIGURATION DESCRIPTION

1 - 737-600/-700/-700C/-800/-900/-900ER series airplanes lines numbers

1 737-700, 737-800 and 737-900 airplanes with FAA APB STC

2 737-600, 737-700, 737-700C, 737-800, 737-900 and 737-900ER

737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Variable Number Group

Original Issue: March 22, 2013

Work Package 1: Left Side Horizontal Stabilizer - Skin Modification

Work Package 2: Right Side Horizontal Stabilizer - Skin Modification

Affected Maintenance Zones

No compliance time is given for the accomplishment of the skin modification.

Boeing recommends this service bulletin be done to introduce improvements.

Original Issue: March 22, 2013

Original Issue: March 22, 2013

Condition Action Compliance Time Repeat Interval

Original Issue: March 22, 2013

Condition Action Compliance Time Repeat Interval

Original Issue: March 22, 2013