February 4, 2013

6-1151-737-PGM-199 Revision 1

Subject:

Model 737NG Elevator Tab Control Mechanism

Reference:

(a)
(b)
(c)

(d)

(e)

Boeing Program Letter 6-1151-737-PGM-196, dated

July 15, 2011
Aft Attach Lug Modification - Boeing Service Bulletin
737-27-1300, dated April 16, 2012
Boeing Service Bulletin 737-27A1297 R1, Elevator Tab
Control Mechanism Detailed Inspection dated
August 2, 2010
Detailed Inspection and Bearing Retainer Installation Boeing Service Bulletin 737-27A1299, published
July 1, 2011
Boeing Program Letter 6-1151-ALL-PGM-197, All Boeing
Aircraft Models Warranty Claim Filing Boeing Service
Letters and Service Bulletins dated August 5, 2011

Dear Customer:
The purpose of this revision is to (i) advise Customers the warranty remedies
offered for the repetitive inspections described in the reference (c) service bulletin
737-27A1297 will expire July 31, 2013 and, (ii) clarify the warranty claim filing
requirements addressed in paragraph 5.a below.
Warranty remedies offered for the inspections described in the reference (d)
service bulletin 737-27A1299 will remain available until Customers have had a
reasonable amount of time to incorporate the terminating action provided in the
reference (b) service bulletin 737-27-1300.
Failure to promptly act upon the reference (b) service bulletin 737-27-1300 will
result in the loss of warranty offered for the reference (d) service bulletin
737-27A1299. To ensure remedies are provided for the reference (d) repetitive
inspections please submit your schedule for the reference (b) incorporation to
your Boeing Warranty Regional Manager for review.
To further support our Customers and encourage prompt incorporation of the
reference (d) service bulletin 737-27A1299, paragraph 5.b below has been revised
to extend the date by which no charge purchase orders for service bulletin kits
must be received from June 30, 2012 to December 31, 2013 for the out of
warranty aircraft.

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This Program Letter cancels and supersedes the reference (a) Program Letter.
The purpose of this Program Letter is to provide information relating to the reference
(b) terminating action Service Bulletin, 737-27-1300, and explain additional support
offered to aid prompt incorporation.
1.

Background:
Several 737NG Customers reported failed aft attach lugs of the elevator tab
mechanism.
The investigation associated with Service Related Problem 737NG-SRP-27-0211
accepted March 11, 2010, revealed the tab mechanism design failures were the result
of a swaging process not capable of achieving the design intent for lug bearing
retention. Accordingly, warranty remedies are available for aircraft, and spare parts
purchased from Boeing, that are in-warranty as of the March 11, 2010 Service Related
Problem acceptance date.
Incorporation of the reference (b) Service Bulletin terminates the actions described in
the reference (c) and (d) Service Bulletins. Warranty remedies for the inspections
described in the reference (c) and (d) Service Bulletins will terminate after Customer
has had reasonable time to incorporate the reference (b) Service Bulletin.
For additional technical information, including the FAA Airworthiness Directive,
AD 2010-17-19, please refer to Fleet Team Digest article 737NG-FTD-27-10005.
2.

Program Intent:
To encourage prompt incorporation of the correction, the following is offered:
a.

All Aircraft Regardless of Warranty Status:

Boeing will provide the following support:

(i)
Service Bulletin materials/kits described in paragraph 2,
Material Information, Part A, Material - Price and Availability of the reference (b)
and (d) Service Bulletins at no-charge.
(ii)

Lug Locating Tool Part Number MIT002A0001-107:

In support of the reference (b) Service Bulletin incorporation,
one (1) each no-charge tool will be provided.
Customers should only order this tool if the intent is to modify the Elevator Tab
in-house or by a Customer-contracted third-party maintenance provider.
When placing your no-charge purchase orders with Material Management please
provide the aircraft identification, Service Bulletin and reference this Program Letter.

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(iii)

Elevator Tab Mechanism Seed Units - No-Charge Lease:

In support of the reference (b) Service Bulletin incorporation, a
limited supply of seed units (i.e., improved configuration) are being made available. A
planned maintenance schedule and execution of a no-charge lease agreement is
required. Please also review Boeing Message MOM-MOM-12-0135-01B dated
March 5, 2012 for additional information about seed unit availability and Elevator Tab
Mechanism exchange options intended to reduce turnaround times as well as
paragraph 4 below for contact information.
It is expected Customers will elect to retain the improved configuration seed units
provided, thus avoiding the additional removal/reinstallation of the original units and a
second flight test. In such cases, the Customer must return an equivalent number of
Customer-owned units, marked as Boeing property, in exchange for the seed units
provided.
(iv)

Ground Support Equipment Parts Numbers C27085 and C27086

These tools aid modification and are available for purchase.

b.

Service Bulletin Labor - Aircraft and Spare Parts Purchased

From Boeing, In-Warranty as of March 11, 2010:
Customers may either perform the Elevator Tab Mechanism
modification described in the reference (b) Service Bulletin or return the mechanism to
Boeing for the modification at no-charge.
Component Repair Services
Boeing Dallas Service Center
2750 Regent Boulevard
Shipping Ramp 2
DFW Airport, Texas 75261

OR

Component Repairs
Boeing Netherlands BV
C/o Aviall Services Inc., Schillingweg 40
2153 PL, Nieuw Vennep
The Netherlands

Customers are eligible for labor reimbursement, commensurate with Service Bulletin
estimates. The following is an example only, published Service Bulletin estimates
may differ. Boeing warranty labor rate for 2012 = $64.55 per hour:
Per Mechanism Per Aircraft
6.0
12.0
10.0

20.0

16.0

32.0

Service Bulletin Labor Estimates

Hours - Open Access, Remove Elevator Tab
Mechanism, Install, Close Access and Test
Hours Disassemble, Modify, Reassemble
Elevator Tab Mechanism
TOTAL hours per aircraft

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$2,065.60
$774.60

Warranty Labor Credit - Per In-Warranty Aircraft

*Customer Performed Modification (32.0 hours)
Boeing Performed Modification (32.0 20.0 = 12.0 hours)

*Customers contracting with a third-party will be responsible for invoices

exceeding the available Boeing warranty remedies.
Customers performing a manual reversion flight test for the sole purpose of
accomplishing Service Bulletin 737-27A1300 (i.e., rather than concurrent with related
maintenance activities that include a flight test) are eligible for a credit in the amount
of US $3,500.00.
Up-front credits are available for the reference (b) Service Bulletin labor hours, as
appropriate.
Labor and flight test reimbursement is not available for aircraft and spare parts whose
warranty expired prior to March 11, 2010. Specifically, Customers electing to have
Boeing modify out-of-warranty Elevator Tabs will be subject to normal repair charges.
4.

Contact Information Support and Warranty Claims:

No-Charge Kits/Materials, Tool

Material Management Parts Page

myboeingfleet@boeing.com

Seed Unit Request

Mr. Dan Paulson

MMRetroFitMods@Boeing.com

In-bound Freight Claims for Boeing

Performed Modifications

Boeing Repair Center

Repairs@Boeing.com

Bulletin Labor Claims

Regional Manager
BCAWarranty@Boeing.com

5.

Program Term:
a.
Aircraft and Spare Parts Purchased From Boeing In-Warranty as of
March 11, 2010:
Consistent with (i) paragraph E, Compliance, of the reference (b)
Service Bulletin which indicates Service Bulletin incorporation within five (5) years of
the original issue, (ii) the reference (e) Program Letter, and (iii) the terms
of the respective Product Assurance Document, to be eligible to claim warranty
remedies Customer must perform within the following periods:

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Five (5) Years from

Initial Bulletin
Service Bulletin 737-27A1300 must be accomplished
Release

One Year

b.

Warranty claims must be received. Up-front

credits are available upon accomplishment of the
first in warranty aircraft, however, warranty
claims must be received as soon as reasonably
possible but in no event later than one year after
accomplishment of the claimed aircraft.

Aircraft and Spare Parts Out-of-Warranty as of March 11, 2010:

No-charge purchase orders must be received no later than:

December 31, 2013

December 31, 2013

Service Bulletin 737-27A1299 - Detailed Inspection

and Bearing Retainer Installation - Interim Action
Service Bulletin 737-27A1300 - Lug Replacement on
the Tab Mechanism - Terminating Action

This Program exceeds our contractual obligations and evidences our continued support
of our delivered products. It does not establish a precedent for any similar or future
issues that might be encountered.
Please contact your BCA Warranty Regional Manager directly with any inquiries you
might have regarding this Program.
Very truly yours,
BOEING COMMERCIAL AIRPLANES
Original Signature on File
D. M. Hurt
Director
Warranty & Product Assurance Contracts