Compliance with AD/B737/161 Amdt 2 requires a structured approach integrated into the aircraft's maintenance program. The steps are based on the AD's text and general regulatory expectations.
Step 1: Confirm applicability. The AD applies to Boeing 737-300, -400, and -500 series. Check the aircraft's registration and type certificate. If the aircraft is one of these, proceed. If not, no further action.
Step 2: Gather required documentation: Boeing Service Letter 737-SL-24-138 dated 24 May 1999; Boeing Special Attention Service Bulletin 737-28-1196, Revision 3 dated 1 April 2004, and (if applicable) earlier revisions (original, Rev 1, Rev 2). Also obtain the aircraft's AD compliance history to determine what has already been done.
Step 3: Determine compliance status for each of the four requirements.
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Check if Requirement 3 (modification) has been accomplished. If yes, verify which service bulletin revision was used and that it is one of the accepted revisions. Also confirm that any corrective action from the modification (Requirement 4) was completed. If the modification is done and accepted, no further inspection is needed. Record this in the AD compliance log.
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If Requirement 3 has not been accomplished, the aircraft is non-compliant. The operator must schedule the modification immediately. Prioritise it because the aircraft cannot lawfully be operated until Requirement 3 is accomplished. However, note that Requirement 1 and 2 also apply until the modification is done. So before flying, the aircraft must have a current Requirement 1 inspection (within the past 24 months) and any discrepancies from that inspection must be repaired. Given the historical deadlines, the operator should probably perform a fresh detailed visual inspection as part of the pre-modification work, even if the last inspection was within 24 months, because the inspection must also confirm condition before modification per the service bulletin.
Step 4: If Requirement 3 is not yet done and the aircraft has never had a Requirement 1 inspection, the operator must perform the detailed visual inspection as defined in the AD. This should be done by a qualified licensed aircraft maintenance engineer (LAME) or under a Part 145 organisation. Use the criteria from the Service Letter. Document all findings. If discrepancies are found, repair them per the Service Letter before further flight. The inspection is terminating once the modification is done, so the operator can choose to combine the inspection with the modification work.
Step 5: Accomplish the modification. This requires purchasing the modification kit (if any) and following the Accomplishment Instructions of the Service Bulletin. The work can be done by an approved maintenance organisation. Ensure that the modification is recorded in the aircraft's logbook, referencing the specific service bulletin revision used. If using an earlier revision, confirm the AD acceptance. After modification, carry out any necessary corrective action identified (e.g., torquing, sealant, additional repairs) before further flight.
Step 6: Update the aircraft's continuing airworthiness records. This includes:
- AD compliance schedule: note that Requirement 1 repetitive inspections are no longer needed because terminating action has been accomplished.
- A signed release to service (Certificate of Release to Service) in accordance with Part 43 or Part 145.
- If the modification was done using an earlier revision, note that it is accepted as per the AD.
Step 7: If the aircraft is operated under an air operator's certificate (AOC), the operator's maintenance control manual should include a procedure for tracking AD compliance. The AD should be added to the maintenance program's AD list with a notation that the modification, once accomplished, eliminates the need for further inspections.
Step 8: If the operator cannot comply within the required timeframe (which is already overdue), they should not fly the aircraft. They must apply to CASA for an alternative means of compliance or a time extension. Given that the AD's deadlines were set in 2005, CASA may require evidence of why compliance was not achieved earlier. While CASA has discretion, it is unlikely to grant a blanket extension; they may require immediate grounding until the modification is done.
Step 9: For a fleet of multiple 737 Classics, prioritise aircraft that are currently active. Use the AD's grandfathering provisions to avoid re-doing work. But if an aircraft has no records of prior modification, assume it is non-compliant and treat it as overdue.
Step 10: Finally, review the AD for any cross-references to FAA ADs. If the aircraft is also maintained under FAA rules, coordinate with the FAA AD compliance schedule to avoid duplication but ensure the stricter requirements are met.
Cost considerations: budget for labour, parts, and downtime. The modification likely requires wiring work in the main wheel well. The AD's costs are borne entirely by the operator; no government support. For a small owner of a single 737-300, the cost could be significant relative to the aircraft's value. However, non-compliance carries enforcement risks and safety risks.
In summary, the most direct path to compliance for any affected aircraft that has not yet been modified is: do a detailed inspection, repair any discrepancies, then perform the modification per the service bulletin, and document everything. After that, the AD is satisfied and requires no further action.