Supplemental Corrosion Program for 737 Cargo Door Modification

PROPRIETARY STATEMENT
THESE TECHNICAL DATA AND THE DESIGNS DISCLOSED HEREIN ARE THE EXCLUSIVE
PROPERTY OF PEMCO WORLD AIR SERVICES, OR CONTAIN PROPRIETARY RIGHTS OF
OTHERS, AND ARE NOT TO BE USED OR DISCLOSED TO OTHERS WITHOUT THE
WRITTEN CONSENT OF PEMCO WORLD AIR SERVICES. THE RECIPIENT OF THIS
DOCUMENT, BY ITS RETENTION AND USE, AGREES TO HOLD IN CONFIDENCE THE
TECHNICAL DATA AND DESIGNS CONTAINED HEREIN. THE FOREGOING SHALL NOT
APPLY TO PERSONS HAVING PROPRIETARY RIGHTS TO SUCH TECHNICAL DATA OR
SUCH DESIGNS TO THE EXTENT THAT SUCH RIGHTS EXIST.
PREPARED BY: DATE: JOB NUMBER:

Rolf Hamerquist 7-28-06 Supplemental Corrosion Prevention and Control Program, Boeing 737-
CHECKED BY: REPORT NUMBER:
300/400, Cargo Door Installation
Jim Felger 7-28-06 2966, Revision E
APPROVED BY: SECTION
Benton Lawson 7-28-06 PEMCO Aircraft Engineering Services, Inc.
APPROVED BY: 1943 50TH STREET NORTH
John Driver 7-28-06 BIRMINGHAM, AL 35212 Page 2 of 59
LIMITATIONS
The selected data contained in this document is prepared solely for the purpose of demonstrating to
regulatory agencies that the inspection methods used are acceptable for showing compliance with their
requirements.
Attempts to use the data in this document to assess the implications of damage, repairs, or modifications
without access to the criteria, background, and ancillary data used to establish the design may result in
invalid and potentially unsafe conclusions.

ABSTRACT
This document presents a supplemental corrosion prevention and control program for a Boeing 737-300
or 737-400 with a forward cargo door modification, associated floor modifications, and with a main
deck class “E” interior installation. This document also presents a supplemental corrosion prevention
and control program for a Boeing 737-400 freighter-passenger combination with a forward cargo door
modification, associated floor modifications, and with a main deck class “C” interior installation.
This program is a supplement to the existing Boeing baseline program to address the modified and
additional structure that is part of the cargo conversion.

LOG OF PAGES INCLUDING REVISION
REVISION REVISED PAGES
DESCRIPTION OF REVISION APPROVAL
NO. DATE PAGE NO.
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E 28-July-06 13
E 28-July-06 14
Added Model 737-400 Freighter-Passenger
E 28-July-06 15
Aircraft
E 28-July-06 16
E 28-July-06 17 Rolled Revision Level For All Pages
E 28-July-06 18
Added Partition and Halon Bottle Support
E 28-July-06 19
Structure Task Card for Model 737-400
E 28-July-06 20 Freighter-Passenger Aircraft
E 28-July-06 21
E 28-July-06 22 Added Model 737-400 Freighter-Passenger
Aircraft Transverse Beam Locations
E 28-July-06 23
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LOG OF PAGES INCLUDING REVISION
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DESCRIPTION OF REVISION APPROVAL
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Aircraft
E 28-July-06 43
E 28-July-06 44 Rolled Revision Level For All Pages
E 28-July-06 45
E 28-July-06 46 Added Partition and Halon Bottle Support
Structure Task Card for Model 737-400
E 28-July-06 47 Freighter-Passenger Aircraft
E 28-July-06 48
E 28-July-06 50 Aircraft Transverse Beam Locations
E 28-July-06 51
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E 28-July-06 53
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TABLE OF CONTENTS
LIMITATIONS....................................................................................................................................................................... 3
ABSTRACT............................................................................................................................................................................ 4
LOG OF PAGES INCLUDING REVISION.......................................................................................................................... 5
TABLE OF CONTENTS........................................................................................................................................................ 7
REFERENCES ....................................................................................................................................................................... 8
DRAWINGS ........................................................................................................................................................................... 9
1. INTRODUCTION ................................................................................................................................................... 1010
1.1 Structural Description...................................................................................................................................... 1111
2. SUPPLEMENTAL CORROSION PROTECTION AND CONTROL PROGRAM .............................................. 1212
2.1 Corrosion Protection........................................................................................................................................ 1212
2.2 Corrosion Repair.............................................................................................................................................. 1212
2.3 Corrosion Inspections ...................................................................................................................................... 1313
2.3.1 Implementation............................................................................................................................................ 1414
2.3.2 Inspection Tasks.......................................................................................................................................... 1515
2.3.2.1 Level 1 Corrosion ............................................................................................................................... 1515
2.3.2.2 Level 2 Corrosion ............................................................................................................................... 1616
2.3.2.3 Level 3 Corrosion ............................................................................................................................... 1616
2.3.2.4 Corrosion Reporting ........................................................................................................................... 1717
2.3.2.5 Explanation of Baseline Task Form ................................................................................................... 1919
2.3.2.6 Fuselage - Exterior Surface ................................................................................................................ 2020
2.3.2.7 Fuselage – Upper Lobe - Interior Surface .......................................................................................... 2121
2.3.2.8 Fuselage – Lower Lobe, Excluding Bilge - Interior Surface.............................................................. 2222
2.3.2.9 Fuselage – Lower Lobe, Bilge - Interior Surface ............................................................................... 2323
APPENDIX A: TASK CARDS ....................................................................................................................................... 2424

REFERENCES
1. Federal Aviation Regulations (FARs), Part 25

2. D6-37635, Boeing 737-300 Series Structural Repair Manual, Rev. 70 dated 10 March 2003
3. D6-37089, “Boeing 737 Supplemental Structural Inspection Document (SSID)”, Revision D, June
1995
4. D6-17594, Maintenance Planning Data (MPD) Document, Rev. N dated 10 Nov. 1990
5. D6-38528 "Aging Airplane Corrosion Prevention and Control Program, Model 737," Revision E
6. D6-37239, Model 737 Nondestructive Test (NDT) Manual, Rev 79 dated 5 April 2003
7. D6-38278, 737-300/400/500 Maintenance Planning Data (Unpublished), November 2002
8. D6-82560, Corrosion Prevention Manual, Rev. 5 dated 1 April 2003
9. PEMCO Report P03-008RM, Boeing 737-200/300/400 Structural Repair Manual Supplement,
Revision 12
10. PEMCO Report P03-007MM, Boeing 737-200/300/400 Supplemental Inspection Document,
Revision 8
11. PEMCO Aircraft Maintenance Manual Supplement, B737 Basic Freighter, STCs’ SA2968SO,
SA2969SO, SA2970SO, and SA2971SO, Initial Issue dated 31 Dec. 1997
12. D6-38246, Boeing 737-400 Structural Repair Manual, Rev 58 dated 10 November 2004
The documents specified as references above, or later FAA approved revisions of the documents
specified as references above, are to be used throughout this document.

DRAWINGS
The current top level drawings that comprise the cargo conversion are included below for reference. It is
recommended that reference 9 be used to determine exact aircraft configuration for specific aircraft serial
number.
Drawing Number Drawing Name
007-00120 Doubler Installation, Cargo Door Mod
007-00200 Jamb Installation, Fwd Cargo Door Mod
007-00300 Aft Jamb Installation, Cargo Door Mod
007-07400 Upper Jamb Installation, Cargo Door Mod
007-00500 Lower Jamb Installation, Cargo Door Mod.
007-09400 Door Installation, Cargo Door Mod
007-09500 Floor Mod
007-04508 9G Bulkhead Instl
007-01600 Net Barrier Installation
0340-53-0008 {1} Partition Instl – B737 Combi
0340-26-0001 {1} Support Installation – Halon Fire Ext. Sys. - Combi
{1} 737-400 Freighter-Passenger Combination Only
For reference, the Main Cargo Door is shown below in Figure 1Figure 1.
Figure 1: Main Cargo Door Assembly

1. INTRODUCTION
This document presents a supplemental corrosion prevention and control program for a Boeing 737-300
or 737-400 with a forward cargo door modification, associated floor modifications, and with a main
deck class “E” interior installation. This document also presents a supplemental corrosion prevention
and control program for a Boeing 737-400 freighter-passenger combination with a forward cargo door
modification, associated floor modifications, and with a main deck class “C” interior installation.
The purpose of this report is to provide information for the inspections and procedures to assure that
airplanes modified in accordance with PEMCO Supplemental Type Certificates (STC’s) maintain an
airworthy state through the timely detection and prevention of corrosion. The inspections included in
this document are a supplement to the existing inspections and procedures specified in reference 7. It is
noted that this document is a supplement to be used in conjunction with reference 7, and it does not
alleviate the requirements of AD 90-25-01.
The new structure that was added as part of this modification uses essentially the same materials as the
existing design. Therefore, it is expected that there will be no significant corrosion impact when
compared to the original configuration. Although there is service history for this modification, it is not
felt that the aircraft have accumulated enough calendar time for corrosion problems, should they exist, to
become apparent.
Therefore, this Supplemental Corrosion Protection and Control Program (CPCP) conservatively
addresses any potential problem with corrosion or stress corrosion. These concerns are addressed by
adding all the new and modified structure to the Baseline Inspection Program called out in reference 7 as
supplements. The supplemental inspections are specified in section 2.3.

1.1 Structural Description
A portion of the existing aircraft monocoque structure bounded by Fuselage Station 360 (one bay aft of
the Forward Entry Door) to Fuselage Station 500, and stringers 3L to 18L, is removed to provide the
opening for the cargo door. The cargo door is attached at the upper edge of the opening through a
segmented piano hinge. The cargo door is attached at the lower edge of the opening through 8 latches.
The structure surrounding the cutout is reinforced with the addition of new structure, and a skin doubler
is added to the exterior of the aircraft. The skin doubler extends from Fuselage Station 312 to 500B, and
stringers 3R to 23L. The aircraft frames, stringers, and skin outside of the Cargo Conversion surround
structure remain the same.
The cutout in the monocoque structure stated above removes the continuous shear and pressure load
path from the aircraft structure. The Cargo Conversion structure is added to the aircraft to allow for the
shear redistribution around the Main Cargo Door cutout. The Main Cargo Door is designed to transfer
pressure loads from the cutout to the Upper and Lower Jambs. The Main Cargo Door is also designed to
transfer induced shear loads from the Upper Jamb to the Lower Jamb.
Figure 2: Main Cargo Door
As part of the cargo conversion, the floor beams are strengthened from the front of the aircraft to the
back of the aircraft. Additionally, a 9G barrier is installed at the front of the cargo compartment to
protect the pilots in an emergency landing or the pallets are restrained with a 9G cargo loading system.

2. SUPPLEMENTAL CORROSION PROTECTION AND CONTROL PROGRAM
2.1 Corrosion Protection
The existing structure remains unchanged as part of the modification. The new structure that was
installed as part of the cargo conversion has the same level of corrosion protection as the existing
structure.
The inspections specified in section 2.3.2 may require the removal of sealant and other forms of
corrosion protection. Corrosion protection in these areas is to be applied in the same fashion as
specified in reference 7, section 10 or reference 8.
2.2 Corrosion Repair

If corrosion is found during the inspections specified in section 2.3.2, the structure is to be repaired in
accordance with reference 2 or 11. Corrosion protection of these repairs is to be applied in accordance
with reference 2 or 9.
If the corrosion detected is not repairable using the information in reference 2 or 9, contact PEMCO
Aircraft Engineering Services, Birmingham, Alabama for assistance to obtain an appropriate repair.

2.3 Corrosion Inspections
This section covers the areas that are required to be inspected to control and prevent corrosion. The
basic task requirements for inspection are the same as given in reference 7, section 10.4.1. Some
information from reference 7, section 10.4.1, is summarized below as it applies to this document.
• Remove all systems, equipment, and interior furnishings, etc…, as necessary to visually inspect
the details called out in section 2.3.2.
• Prior to inspection, clean the area as necessary to visually inspect the details called out in section
2.3.2. It is not necessary to remove normal amounts of sealant or leveling compound unless it
has deteriorated to the point where moisture can penetrate down to the metal.
o A light uniform layer of corrosion inhibiting compound (CIC), that has not accumulated
dirt or debris will normally allow adequate inspection of the structure without removal.
CIC may require removal if there are multiple layers and/or accumulations of dirt or
debris.
• Visually inspect the details specified in section 2.3.2 using surveillance inspection methods in
order to detect early stages of corrosion or indications of other discrepancies, such as cracking.
Pay particular attention to the listed areas in section 2.3.2, where corrosion may occur.
• Use additional non-destructive inspections or visual inspections following partial disassembly if

there are indications of hidden corrosion, such as bulging skins or corrosion running into splices,
under fittings, etc…, in the task area.
Additional information required for the basic task inspections is given in reference 7, section 10.4.1.

2.3.1 Implementation
The 737-300/400 Supplemental Corrosion Prevention and Control Program is subdivided into specific
airplane task areas and locations for this modification, each having an implementation age ((I), years
since modification) and repeat interval (R) for application of the Basic Task (reference sections 2.3.2.5,
2.3.2.6, 2.3.2.7, 2.3.2.8, and 2.3.2.9 for implementation age (I) and repeat interval (R)). Each Basic
Task corresponds to an existing Basic Task specified in reference 7. The task areas and locations are
applicable to a 737-300 or 737-400 airplane modified in accordance with Supplemental Type
Certificates (STC’s) SA2968SO, SA2969SO, and SA2970SO. These inspections are to be carried out
prior to, or at the given airplane age (I); or within (I) + the specified repeat interval (R).
It is required that implementation of each Baseline Program task (first application of the CPCP Task, see
reference 7) on all affected 737-300 or 737-400 airplanes be accomplished during any convenient
maintenance visit, but prior to the airplane exceeding an age corresponding to [(I, years since delivery) +
(R)] for each respective task. It is recommended that the inspections specified in this document be
combined with the existing inspection programs specified in reference 7.
Components removed from a currently airworthy airplane, then installed on a different airplane, can be
transferred to that airplane's CPCP, provided they are inspected and signed-off by quality control before
they are installed on the new airplane. Such components are to be visually inspected from a distance
considered necessary to detect early stages of corrosion or indications of other discrepancies such as
cracking (e.g., surveillance inspection).
If there are indications of hidden corrosion, such as bulging skins, corrosion running into splices or
under fittings, etc., additional inspections or partial disassembly is required.
For airplanes that are approaching or have already exceeded [(I) + (R)], implement the applicable tasks
with a schedule approved by the appropriate regulatory authority. It is noted that this document is a
supplement to be used in conjunction with reference 7, and it does not alleviate the requirements of AD
90-25-01.

2.3.2 Inspection Tasks
The Basic Tasks contained in this section are comparable to the Basic Tasks given in reference 7, and
are numbered accordingly. Each subsection specifies the airplane area to be examined. All airplanes
modified in accordance with PEMCO Supplemental Type Certificates (STC’s) are to be inspected in
accordance with the requirements of this document. It is noted that this document is a supplement to be
used in conjunction with reference 7, and it does not alleviate the requirements of AD 90-25-01.
The objective is to prevent or control corrosion problems that may jeopardize continuing airworthiness
of Boeing 737-300 or 737-400 airplanes that have a cargo conversion modification. The purpose of this
document is to define minimum procedures for meeting the program objective. To accomplish this, a
baseline program (given as part of section 2.3) was developed by PEMCO Engineering Aircraft
Services, for use by operators who do not have an existing effective Supplemental Corrosion Prevention
and Control Program (CPCP). The effectiveness of a CPCP is determined by the "level" of corrosion
found on structure listed in this program. The following corrosion level definitions are applicable to each
task in this program (the same definitions are used in reference 7 in section 10.2).
2.3.2.1 Level 1 Corrosion

o Corrosion damage occurring between successive inspections, that is local and can be re-
worked/blended-out within allowable limits as defined by the PEMCO (e.g. SRM; SB; etc.).
o Corrosion damage occurring between successive inspections that is widespread and can be
reworked/blended-out well below allowable limits as defined by the PEMCO.
o Corrosion damage that exceeds allowable limits and can be attributed to an event not typical of
the operator's usage of other airplanes in the same fleet (e.g. Mercury spill). Report any level 3
corrosion findings in accordance with paragraph B. of AD 90-25-01.
o Operator experience over several years has demonstrated only light corrosion between
successive inspections but latest inspection and cumulative blend-out now exceed allowable
limit.

o Corrosion occurring between a successive inspection that requires a single re-work/blend-out
which exceeds allowable limits, requiring a repair/reinforcement or complete or partial
replacement of a structural component, element or detail listed in this program.
o Corrosion occurring between successive inspections that is widespread and requires a single
blend-out approaching allowable re-work limits.

o Corrosion found during the first or subsequent inspections, which is determined (normally by the
operator) to be an urgent airworthiness concern requiring expeditious action.
o Level 3 corrosion is to be reported and addressed in accordance with paragraph B of AD 90-25-
01.
When Level 3 corrosion is found consideration should be given to action required on other airplanes in
the operator's fleet in accordance with paragraph B of AD 90-25-01. Details of the corrosion findings
and planned action(s) should be expeditiously reported to the appropriate regulatory authority.
AN EFFECTIVE PROGRAM IS ONE THAT CONTROLS CORROSION OF ALL

STRUCTURE LISTED IN THE BASELINE PROGRAM TO LEVEL 1 OR BETTER.

2.3.2.4 Corrosion Reporting
In addition to the routine reporting procedures already established for the 737-300/400 for the PEMCO
cargo conversion; this Supplemental Corrosion Prevention Control Program includes an additional
reporting system. The primary purpose of this system is to provide data for monitoring the effectiveness
of this program and determining any necessary changes.
Starting with the first application of each CPCP task, report all Level 2 and Level 3 corrosion findings
on structure listed in this inspection program, to PEMCO Engineering Aircraft Services. Report all
Level 3 corrosion findings in accordance with paragraph B of AD 90-25-01. A form for submitting a
summary of each finding and related information is included in section 2.3.2.4.1. Operators should
complete all pertinent sections of the form to the extent practical. Any additional comments and/or
photographs, that are available and help to identify the corrosion problem area or type, should be
attached. It is recommended, but not required to report the following occurrences of corrosion.
o Level 1 corrosion found during the first application of a CPCP task. Although it is not
necessary, operators are requested to submit data of significant corrosion found during first
application of the CPCP tasks.
o Corrosion found by a means other than a CPCP task. Although it is not necessary, operators are
requested to submit data on significant corrosion found outside the CPCP, with a note stating
how and when the corrosion was found.
o Corrosion on structural parts or components, or systems components not included in the task
descriptions.
All reports and data dealing with the 737-300/400 Supplemental Corrosion Prevention Control Program
should be submitted through a PEMCO Field Service Representative. It is also acceptable to either fax
or e-mail data dealing with the 737-300/400 Supplemental Corrosion Prevention Control Program to:
Director Of Product Support

Pemco Aircraft Engineering Services
1943 50th Street North
Birmingham, Alabama 35212
Voice and Fax Number: (205) 510-4972
E-mail: john.driver@pemcoair.com
If damage other than corrosion is found during this inspection, that damage is to be reported to PEMCO
at the above address.

2.3.2.4.1 Corrosion Reporting Form
CORROSION PREVENTION AND CONTROL PROGRAM - INSPECTION REPORT
OPERATOR: INSPECTION DATE:

MODEL: LINE NUMBER:
SERIAL NUMBER: TAIL NUMBER:
MAINTENANCE OR REPAIR FACILITY:
CORROSION TASK NUMBER:
INTERVAL (YEARS) SINCE LAST INSPECTION:
LEVEL OF CORROSION
LEVEL 2 LOCAL
LEVEL 3 WIDESPREAD
DAMAGED PART IDENTIFICATION
LONGERON/STRINGER
FRAME SKIN
BRACKET/SHEAR TIE DOUBLER
CHORD RIB
WEB BULKHEAD
OTHER FITTING
LOCATION OF DAMAGE
STATION TO STATION
STRINGER L/R TO STRINGER L/R
WATERLINE WATERLINE
BUTTLINE L/R BUTTLINE L/R
CAUSE OF DAMAGE
ENVIRONMENT INTERNAL LEAKAGE
CHEMICAL SPILL LAV./GALLEY SPILL
BLOCKED DRAIN WET INSULATION BLANKET
UNKNOWN
OTHER
ADDITIONAL DESCRIPTION OF DAMAGED AREA:
PEMCO Report 2966 Revision E, Supplemental Corrosion Prevention and Control Program, Boeing 737-300/400, Cargo Door Installation Page 18 of 59
2.3.2.5 Explanation of Baseline Task Form
An explanation of the form used to list the baseline program tasks is given below. This information is modeled on the information presented in
reference 7, section 10. The aircraft zone number is the same as given in reference 7, section 3.
AIRPLANE AREA: Description of the airplane area in which all the listed tasks, having the same zone number within the CORROSION TASK
NUMBER, are located.
CORROSION TASK NUMBER: Identifies a specific airplane area, or location within the area, for application of the BASIC or other defined corrosion task. The
numbering system consists of an ATA code index, Zone and Item Number. Sub-Item numbers are used to identify specific areas
requiring particular attention during general area inspections.
Example: C53-202-01.01S
C Identifies the task as corrosion related.

53 The ATA Chapter Code that best describes the airplane area.
202 The Zone Number associated with the airplane area. When multiple zones are affected a Major or Sub-Major, or the lowest zone number is used (refer
to the information in references 5 or 7).
01 A sequential Task Item Number associated with the airplane area.
.01 A sequential Sub-Item Number identifying an area/item requiring particular attention (typically requiring a surveillance inspection) during inspections
of a given airplane area, but not warranting a separate task.
S Defining the item as a supplement to the existing inspection program (refer to reference 7).
DESCRIPTION OF STRUCTURE IN CPCP TASK: Description of structure to which the given corrosion task applies.
ZONES: List of airplane zones to which the given corrosion task applies.
EFFECTIVITY: The airplane model-series and/or line number to which the given corrosion task applies.
IMPLEMENTATION AGE (I): Airplane age, in terms of years since initial delivery from PEMCO, beyond which the above CPCP
task must be implemented per section 2.3.1.
REPEAT INTERVAL (R): The interval, in terms of years, between repeat applications of the above CPCP Task.
REFERENCE SERVICE BULLETINS: Numbers of Service Bulletins that include task descriptions or additional supporting information, for
use with the given Baseline Program tasks.
NOTES: Additional information relative to a given task, shown as a reference number in the right hand column
with a corresponding explanation.
2.3.2.6 Fuselage - Exterior Surface
The cargo conversion includes the addition of external doublers and a main deck cargo door (reference section 1.1 for a description of the
location of the external doublers and cargo door cutout). This impacts the inspections of these areas (reference 7) by covering the exterior of
the aircraft. The following table specifies the basic task for the area of the modification covering the exterior of the aircraft.
CORROSION TASK I R REFERENCE
NUMBER DESCRIPTION OF AREA TO BE INSPECTED ZONES EFFECTIVITY YRS YRS SB’S NOTE
Exterior surface of the fuselage from BS 294.5 to BS 500C and stringer 5R to 28L
including skin panels, main cargo door, passenger entry door, external doublers, and 105, 107, 206,
C53-100-01S ALL 6 3 - [1]
cutouts. Exterior surface of the fuselage from BS 344 to BS 360 and stringer 5R to 17R. 207, and 208
Pay particular attention to the following areas:
C53-100-01.01S Longitudinal Doubler Butt Splices -
C53-100-01.02S Circumferential Doubler Butt Splices -
C53-100-01.03S Window Belt -
C53-100-01.04S Cargo Door Segmented Hinge (Attaching Cargo Door to Fuselage at Upper Edge) 107 ALL 3 3 -
[1] Zones 206 and 207 refer to the airstair and airstair compartment if the airstair is installed.
Table 2-1: Fuselage, Exterior Surface Inspections
The inspection requirements given above are a supplement to the existing Boeing Corrosion Prevention Control programs and do not alleviate
the requirements of AD 90-25-01. Report details of the inspection findings per section 2.3.2.4 of this document and per the requirements of the
applicable regulatory authority. Report all Level 3 corrosion findings in accordance with paragraph B of AD 90-25-01.
2.3.2.7 Fuselage – Upper Lobe - Interior Surface
The cargo conversion includes the addition of an upper, lower, forward, and aft jamb and a main deck cargo door (reference section 1.1 for a
description of the location of the internal structure and cargo door cutout). Additionally, there is a 9G barrier included forward of the cargo
compartment. For the 737-400 Freighter-Passenger combination only, there is a partition installed at BS612. This impacts the inspections of
these areas (reference 7) by modifying the interior of the aircraft. The following table specifies the basic task for the area of the modification
covering the interior of the aircraft.
Interior surface of the fuselage from BS 294.5 to BS 500C and stringer 5R to 17L
including skin panels, stringers, main cargo door, passenger entry door, frames, jambs,
and cutouts. Interior surface of the fuselage from BS344 to BS360 and stringer 5R to
C53-107-01S 105 and 107 ALL 6 6 - [3]
17R. Honeycomb bulkhead or 9G Net from Stringer 17L to 17R from BS349 to BS353.
For 737-400 Freighter-Passenger Only, honeycomb partition at FS612. Pay particular
attention to the following areas:
C53-107-01.01S PEMCO Upper Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500) -
C53-107-01.02S PEMCO Upper Jamb Sill (at Edge of Cargo Door Opening) -
C53-107-01.03S PEMCO Forward Jamb (FS 344 and 360) -
C53-107-01.04S PEMCO Aft Jamb (FS 500 and 500A) -
C53-107-01.05S PEMCO Main Cargo Door Outer Skin at Intercostals -
C53-107-01.06S PEMCO Aft Jamb (FS 500) 107 3 3 - [1]
C53-107-01.07S PEMCO Forward Jamb (FS 360) 107 3 3 - [1]
C53-107-01.08S PEMCO Cargo Door Upper Sill 107 3 3 - [1]
C53-107-01.09S Hydraulic Actuators 107 3 3 - [1], [2]
C53-107-01.10S Periphery of the Honeycomb Bulkhead 107 3 3 - [3]
C53-107-01.11S Periphery of the 9G net 107 3 3 - [3]
C53-107-01.12S Partition Attachments to Fuselage and Seat Track Structure at BS612 107 3 3 - [4]
[1] These inspections are to be performed with the cargo door in the open position. It is not necessary to remove any of the interior structure to gain access for these
inspections.
[2] Check the vicinity of the hydraulic actuators for signs of leakage.
[3] Of the Honeycomb Bulkhead and the 9G Net, only one or the other is installed in each modified aircraft.
[4] Partition is installed in Freighter-Passenger Combination only
Table 2-2: Fuselage, Upper Lobe, Interior Surface Inspections
2.3.2.8 Fuselage – Lower Lobe, Excluding Bilge - Interior Surface
description of the location of the internal structure and cargo door cutout). This also includes the floor beam modifications to support the cargo
requirements. For the 737-400 Freighter-Passenger combination only, there are halon bottles installed. This impacts the inspections of these
areas (reference 7) by modifying the interior of the aircraft. The following table specifies the basic task for the area of the modification
covering the interior of the aircraft.
Interior surface of the fuselage from BS 294.5 to BS 500C and stringer 17L to 25L
including skin panels, stringer, main cargo door, frames, jambs, and cutouts. Modified
transverse floor beams including those at BS 360, 460, 500, 500B and BS 727B through
BS 1006 (Model 737-300). Modified transverse floor beams including those at BS 360,
C53-202-01S 400, 500, 500D, 500F, 520 and BS 727B through BS 1006 (Model 737-400 Freighter). 202 and 218 ALL 6 6 -
Modified transverse floor beams including those at BS 360, 400, 500, 500D, 500F, and
520 (Model 737-400 Passenger-Freighter Combination). Halon bottle installation
between BS847 and BS927, and LBL 20 and LBL 60 (737-400 Passenger-Freighter
Combination). Pay particular attention to the following areas:
C53-202-01.01S PEMCO Lower Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500) -
C53-202-01.02S PEMCO Lower Jamb Sill (at Edge of Cargo Door Opening) -
C53-202-01.05S PEMCO Main Cargo Door Outer Skin at Lower Edge -
PEMCO Jamb Frames (FS 344, 360, 380, 400, 420, 440, 460, 490, 500, and 500A)
C53-202-01.06S -
attachment to Boeing Floor Beams
C53-202-01.07S PEMCO Aft Jamb (FS 500) 202 3 3 - [1]
C53-202-01.08S PEMCO Forward Jamb (FS 360) 202 3 3 - [1]
C53-202-01.09S PEMCO Cargo Door Lower Sill 202 3 3 - [1]
C53-202-01.010S Latch Fittings 202 3 3 - [1]
C53-202-01.011S Halon Bottle Support Attachments to Frames and Floor Beams 218 3 3 - [2]
[1] These inspections are to be performed with the cargo door in the open position. It is not necessary to remove any of the interior structure to gain access for these
inspections.
[2] Partition is installed in Freighter-Passenger Combination only
Table 2-3: Fuselage, Lower Lobe, Excluding Bilge, Interior Surface Inspections
2.3.2.9 Fuselage – Lower Lobe, Bilge - Interior Surface
description of the location of the internal structure and cargo door cutout). This impacts the inspections of these areas (reference 7) by
modifying the interior of the aircraft. The following table specifies the basic task for the area of the modification covering the interior of the
aircraft.
Interior surface of the fuselage from BS 294.5 to BS 500C and stringer 25L to 28L
C53-202-02S including skin panels, stringers, frames, jambs, and cutouts. Pay particular attention to 202 ALL 6 6 - [1]
the following areas:
C53-202-02.01S PEMCO Lower Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500) -
[1] From reference 7 for corrosion task number C53-202-01, the following note is given: “1) a dual coat of corrosion inhibitor per basic task part 6B) is recommended
for areas under galleys and lavs., skin at toilet service panels, structure under the airstairs (if installed, and structure described in C53-202-01-09 (optional).”
Table 2-4: Fuselage, Lower Lobe, Bilge, Interior Surface Inspections
the requirements of AD 90-25-01.
Report details of the inspection findings per section 2.3.2.4 of this document and per the requirements of the applicable regulatory authority.
Report all Level 3 corrosion findings in accordance with paragraph B of AD 90-25-01.
APPENDIX A: TASK CARDS
PEMCO Report 2966, Revision E, Supplemental Corrosion Prevention and Control Program,
Boeing 737-300/400, Cargo Door Installation Task Cards Page 24 of 59
PLANNER: AIRCRAFT TYPE: ASSIGNED SUPV: PAGE NO.
B737-300/400 TELEPHONE: ___ OF ___
AIRCRAFT MFR NO. AIRCRAFT REG NO. PEMCO AIRCRAFT ID NO. DATE WORK ORDER NO.
C53-100-01S
TASK TITLE: CHECK EXTERIOR OF FUSELAGE
AIRCRAFT CYCLES: _______________ IMPLEMENTATION AGE (I) YRS

AIRCRAFT HOURS: _______________ AFTER MODIFICATION: 6
AIRCRAFT CYCLES AFTER MODIFICATION: _______________
REPEAT INTERVAL (R) YRS
AIRCRAFT HOURS AFTER MODIFICATION: _______________ AFTER MODIFICATION: 3
DESCRIPTION OF WORK MECHANIC INSPECTOR
Exterior surface of the fuselage from BS 294.5 to BS 500C and stringer

5R to 28L including skin panels, main cargo door, passenger entry
door, external doublers, and cutouts. Exterior surface of the fuselage
from BS 344 to BS 360 and stringer 5R to 17R.
ACCESS REQUIREMENTS: HIGHEST CORROSION LEVEL

NONE
INSPECTION RESULTS: NONE 1 2 3
B737-300/400 TELEPHONE: ___ OF ___
C53-100-01.01S
TASK TITLE: CHECK EXTERIOR OF FUSELAGE – LONGITUDINAL

DOUBLER BUTT SPLICES

Longitudinal Doubler Butt Splices visible from the exterior surface of the
fuselage from BS 294.5 to BS 500C and stringer 5R to 28L.

NONE
B737-300/400 TELEPHONE: ___ OF ___
C53-100-01.02S
TASK TITLE: CHECK EXTERIOR OF FUSELAGE - CIRCUMFERENTIAL

DOUBLER BUTT SPLICES

Circumferential Doubler Butt Splices visible from the exterior surface of

the fuselage from BS 294.5 to BS 500C and stringer 5R to 28L.

NONE
B737-300/400 TELEPHONE: ___ OF ___
C53-100-01.03S
TASK TITLE: CHECK EXTERIOR OF FUSELAGE - WINDOW

Window Belt visible from the exterior surface of the fuselage from BS
294.5 to BS 500C and stringer 5R to 28L.

NONE
B737-300/400 TELEPHONE: ___ OF ___
C53-100-01.04S
TASK TITLE: CHECK EXTERIOR OF FUSELAGE – SEGMENTED HINGE

Cargo Door Segmented Hinge visible from the exterior surface of the
fuselage from BS 294.5 to BS 500C and stringer 5R to 28L.

NONE
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01S
TASK TITLE: CHECK INTERIOR OF FUSELAGE

Interior surface of the fuselage from BS 294.5 to BS 500C and stringer

5R to 17L including skin panels, stringers, main cargo door, passenger
entry door, frames, jambs, and cutouts. Interior surface of the fuselage
from BS344 to BS360 and stringer 5R to 17R. Honeycomb bulkhead or
9G Net from Stringer 17L to 17R from BS349 to BS353.

REMOVAL OF INTERIOR PANELS AND INSULATION BLANKETS AS REQUIRED.
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.01S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Upper Jamb

Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500)

PEMCO Upper Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480,
490, and 500) visible from the interior surface of the fuselage from BS
294.5 to BS 500C and stringer 5R to 17L.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.02S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Upper Jamb Sill (at
Edge of Cargo Door Opening)

PEMCO Upper Jamb Sill (at Edge of Cargo Door Opening) visible from
the interior surface of the fuselage from BS 294.5 to BS 500C and
stringer 5R to 17L.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.03S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Forward Jamb (FS

344 and 360)

PEMCO Forward Jamb (FS 344 and 360) visible from the interior
surface of the fuselage from BS 294.5 to BS 500C and stringer 5R to
17L.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.04S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Aft Jamb (FS 500
and 500A)

PEMCO Aft Jamb (FS 500 and 500A) visible from the interior surface of
the fuselage from BS 294.5 to BS 500C and stringer 5R to 17L.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.05S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Main Cargo Door

Outer Skin at Intercostals

PEMCO Main Cargo Door Outer Skin at Intercostals visible from the
interior surface of the fuselage from BS 294.5 to BS 500C and stringer
5R to 17L.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.06S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Aft Jamb (FS 500)

PEMCO Aft Jamb (FS 500) visible from the exterior and interior surface
of the fuselage with the cargo door in the open position.

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.07S

360)

PEMCO Forward Jamb (FS 360) visible from the exterior and interior
surface of the fuselage with the cargo door in the open position.

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.08S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Cargo Door Upper

Sill

PEMCO Cargo Door Upper Sill visible from the exterior and interior

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.09S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - Hydraulic Actuators

Hydraulic Actuators visible from the exterior and interior surface of the
fuselage with the cargo door in the open position.

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.10S
TASK TITLE: CHECK INTERIOR OF FUSELAGE – Periphery of Honeycomb

Bulkhead

Periphery of the Honeycomb Bulkhead located between BS 349 and

BS 353 visible from the aft side and forward side of the bulkhead.

B737-300/400 TELEPHONE: ___ OF ___
C53-107-01.11S
TASK TITLE: CHECK INTERIOR OF FUSELAGE – Periphery of 9G Net

Periphery of the 9G Net, at the fuselage and floor attachments, located

between BS 343 and BS 441 visible from the aft side and forward side
of the net.

B737-400 Freighter- TELEPHONE: ___ OF ___

Passenger Only
C53-107-01.12S
TASK TITLE: CHECK INTERIOR OF FUSELAGE – Partition Attachments to

Fuselage and Seat Track Structure at BS612

Partition attachments to fuselage at stringers 5, 7, 9, 13, and 16 left and

right. Partition attachments to seat tracks at LBL and RBL 45.5.

B737-300/400 Quick TELEPHONE: ___ OF ___

Change or Freighter
C53-202-01S


17L to 25L including skin panels, stringer, main cargo door, frames,
jambs, and cutouts. Modified transverse floor beams including those at
BS 360, 460, 500, 500B and BS 727B through BS 1006 (Model 737-
300). Modified transverse floor beams including those at BS 360, 400,
500, 500D, 500F 520 and BS 727B through BS 1006 (Model 737-400).

REMOVAL OF INTERIOR PANELS, FLOOR BOARDS, AND INSULATION
BLANKETS AS REQUIRED.

Passenger Only
C53-202-01S


17L to 25L including skin panels, stringer, main cargo door, frames,
jambs, and cutouts. Modified transverse floor beams including those at
BS 360, 400, 500, 500D, 500F, and 520 (Model 737-400 Passenger-
Freighter Combination).

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.01S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Lower Jamb

Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500)

PEMCO Lower Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480,
490, and 500) visible from interior surface of the fuselage from BS
294.5 to BS 500C and stringer 17L to 25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.02S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Lower Jamb Sill (at
Edge of Cargo Door Opening)

PEMCO Lower Jamb Sill (at Edge of Cargo Door Opening) visible from
17L to 25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.03S

344 and 360)

PEMCO Forward Jamb (FS 344 and 360) visible from interior surface
of the fuselage from BS 294.5 to BS 500C and stringer 17L to 25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.04S
and 500A)

PEMCO Aft Jamb (FS 500 and 500A) visible from interior surface of the
fuselage from BS 294.5 to BS 500C and stringer 17L to 25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.05S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Main Cargo Door

Outer Skin at Lower Edge

PEMCO Main Cargo Door Outer Skin at Lower Edge visible from
17L to 25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.06S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Jamb Frames (FS

344, 360, 380, 400, 420, 440, 460, 490, 500, and 500A)
attachment to Boeing Floor Beams

PEMCO Jamb Frames (FS 344, 360, 380, 400, 420, 440, 460, 490,
500, and 500A) attachment to Boeing Floor Beams visible from interior
surface of the fuselage from BS 294.5 to BS 500C and stringer 17L to
25L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.07S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Aft Jamb (FS 500)

PEMCO Aft Jamb (FS 500) visible from the exterior and interior surface
of the fuselage with the cargo door in the open position.

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.08S

360)

PEMCO Forward Jamb (FS 360) visible from the exterior and interior

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.09S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Cargo Door Lower

Sill

PEMCO Cargo Door Lower Sill visible from the exterior and interior
surface of the fuselage with the cargo door in the open position

OPEN CARGO DOOR.
B737-300/400 TELEPHONE: ___ OF ___
C53-202-01.10S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - Latch Fittings

PEMCO Cargo Door Latch Fittings visible from the exterior and interior

OPEN CARGO DOOR.

Passenger Only
C53-202-01.11S
TASK TITLE: CHECK INTERIOR OF FUSELAGE – Halon bottle support

attachments to frames an floor beams.

Visual Halon bottle installation between BS847 and BS927, and LBL 20
and LBL 60. Support structure is attached to each of the fuselage
frames at two locations and to floor beam at one location.

ENTER AIRCRAFT THROUGH AFT LOWER CARGO DOOR. REMOVAL OF
CARGO LINER AS REQUIRED.
B737-300/400 TELEPHONE: ___ OF ___
C53-202-02S


25L to 28L including skin panels, stringers, frames, jambs, and cutouts.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-02.01S
TASK TITLE: CHECK INTERIOR OF FUSELAGE - PEMCO Lower Jamb

Frames (FS 370, 380, 400, 420, 440, 460, 480, 490, and 500)

PEMCO Lower Jamb Frames (FS 370, 380, 400, 420, 440, 460, 480,
490, and 500) visible from interior surface of the fuselage from BS
294.5 to BS 500C and stringer 25L to 28L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-02.02S

344 and 360)

PEMCO Forward Jamb (FS 344 and 360) visible from interior surface
of the fuselage from BS 294.5 to BS 500C and stringer 25L to 28L.

B737-300/400 TELEPHONE: ___ OF ___
C53-202-02.03S
and 500A)

PEMCO Aft Jamb (FS 500 and 500A) visible from interior surface of the
fuselage from BS 294.5 to BS 500C and stringer 25L to 28L.


Supplemental Corrosion Program for 737 Cargo Door Modification

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PROPRIETARY STATEMENT

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

REVISION REVISED PAGES

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

1. Federal Aviation Regulations (FARs), Part 25

PREPARED BY: DATE: JOB NUMBER:

{1} 737-400 Freighter-Passenger Combination Only

Figure 1: Main Cargo Door Assembly

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

Figure 2: Main Cargo Door

PREPARED BY: DATE: JOB NUMBER:

2.2 Corrosion Repair

PREPARED BY: DATE: JOB NUMBER:

• Use additional non-destructive inspections or visual inspections following partial disassembly if

PREPARED BY: DATE: JOB NUMBER:

PREPARED BY: DATE: JOB NUMBER:

2.3.2.1 Level 1 Corrosion

PREPARED BY: DATE: JOB NUMBER:

2.3.2.3 Level 3 Corrosion

AN EFFECTIVE PROGRAM IS ONE THAT CONTROLS CORROSION OF ALL

PREPARED BY: DATE: JOB NUMBER:

Director Of Product Support

PREPARED BY: DATE: JOB NUMBER:

CORROSION PREVENTION AND CONTROL PROGRAM - INSPECTION REPORT

OPERATOR: INSPECTION DATE:

DAMAGED PART IDENTIFICATION

ADDITIONAL DESCRIPTION OF DAMAGED AREA:

C Identifies the task as corrosion related.

Table 2-1: Fuselage, Exterior Surface Inspections

Table 2-4: Fuselage, Lower Lobe, Bilge, Interior Surface Inspections

B737-300/400 TELEPHONE: ___ OF ___

TASK TITLE: CHECK EXTERIOR OF FUSELAGE

AIRCRAFT CYCLES: _______________ IMPLEMENTATION AGE (I) YRS

DESCRIPTION OF WORK MECHANIC INSPECTOR

Exterior surface of the fuselage from BS 294.5 to BS 500C and stringer

ACCESS REQUIREMENTS: HIGHEST CORROSION LEVEL

INSPECTION RESULTS: NONE 1 2 3

B737-300/400 TELEPHONE: ___ OF ___

TASK TITLE: CHECK EXTERIOR OF FUSELAGE – LONGITUDINAL

AIRCRAFT CYCLES: _______________ IMPLEMENTATION AGE (I) YRS

DESCRIPTION OF WORK MECHANIC INSPECTOR

ACCESS REQUIREMENTS: HIGHEST CORROSION LEVEL

INSPECTION RESULTS: NONE 1 2 3

B737-300/400 TELEPHONE: ___ OF ___

TASK TITLE: CHECK EXTERIOR OF FUSELAGE - CIRCUMFERENTIAL

AIRCRAFT CYCLES: _______________ IMPLEMENTATION AGE (I) YRS

DESCRIPTION OF WORK MECHANIC INSPECTOR

Circumferential Doubler Butt Splices visible from the exterior surface of

ACCESS REQUIREMENTS: HIGHEST CORROSION LEVEL

INSPECTION RESULTS: NONE 1 2 3

B737-300/400 TELEPHONE: ___ OF ___

TASK TITLE: CHECK EXTERIOR OF FUSELAGE - WINDOW

AIRCRAFT CYCLES: _______________ IMPLEMENTATION AGE (I) YRS

DESCRIPTION OF WORK MECHANIC INSPECTOR

ACCESS REQUIREMENTS: HIGHEST CORROSION LEVEL

INSPECTION RESULTS: NONE 1 2 3

B737-300/400 TELEPHONE: ___ OF ___

TASK TITLE: CHECK EXTERIOR OF FUSELAGE – SEGMENTED HINGE

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _

B737-300/400 TELEPHONE: _ OF _