(4)  
Examine door operating mechanism for cracks, corrosion, excessive wear, and loose bolts.

(5)  
Examine latch rollers, latches, and door stops for cracks, corrosion and foreign particles lodged in latches or attached to stops.

(6)  
Examine drain holes for obstruction.

(7)  
Examine door seals for cracks, cuts and tears, and correct seating when door is in closed position.

(8)  
Examine roller cam plates and guide arm roller for excessive wear, which may cause door to malfunction (Ref 52-11-21 - Removal/Installation.

(a)  Check for excessive wear (elongation) of latch pin hole in upper roller guide plate. (Hole may wear 0.06 inch oversize to a maximum diameter (part number 65-29993-2 only) of 0.4078 inch.)

(9)  
Check that snubber operates correctly to retard or snub rapid motion of the door towards stowed and cocked positions.

(10)
Examine door stops for misalignment, using the door stop pin bearing marks on frame stop buttons (Fig. 601).

NOTE:  Door stop bearing marks are a result of flight plus fuselage pressure loads. Check must be performed with airplane on its wheels.

(11)
Check door flushness requirements shown in Fig. 602.

NOTE:  Measurements of flushness are to be made only at points along straight sections between rounded corners of door skin. Check must be performed with airplane on its wheels.
508 
Aug 15/78  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  52-11-0 Page 601 

Typical Door Stop Misalignment Data  500 
52-11-0  Figure 601  Feb 20/94 
Page 602 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

(12) Check fuselage and door outside skin gap measurements with airplane on its wheels.
(a)
Gap around upper gate should be 0.12 ±0.06 inch.

(b)
Gap along forward and aft edge of door should be 0.09 +0.09/.0.03 inch.

(c)
Deleted

(d)
Gap at bottom of lower gate should be 0.15 +0.06/.0.09 inch.

500  Forward Entry Door Flushness Requirements 
Feb 20/91  Figure 602  52-11-0 
Page 603 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

FORWARD ENTRY DOOR - APPROVED REPAIRS
1. General
A.  Elongation of top roller guide plate 65-29993-2 latch pin hole can result in latch pin disengaging and door blowing closed under high wind conditions. A repair procedure to restore latch pin open hole to original design dimensions follows. Latch pin hole may wear 0.06 inch oversize to a maximum diameter of 0.4078 inch before repair is required.
B.  Ovalization of the bolt holes through which the bolts are installed that assemble the forward entry door torque tube, torque tube sleeve, and hinge pin may cause the entry door to sag on its hinges. If this condition is encountered, the bolt holes in these parts may be oversized one-sixteenth inch to eliminate ovalness and oversized bolts installed. Refer to par. 4 for repair procedure.
C.  Repair of forward entry door fuselage mounted door stops may be accomplished as a basic repair (Ref par. 6).
2.  Equipment and Materials
A.  Spotfacing fixture, guide plate latch pin hole - fabricate fixture to allow spotfacing 65-29993-2 guide plate latch pin hole to 0.08 inch depth and 0.593 inch diameter with guide plate either on or off airplane per step 3.A. below.
B.  Bushing , 17-4PH stainless steel - fabricate to meet requirements of step 3.C.
C.  Alodine 1200 - MIL-C-5541 (Ref 20-30-41)
D.  Chemical and Solvent Resistant Finish - BMS 10-11, Type I (Ref 20-30-41)
E.  Assembly Tool, Latch Roller, Entry Door - ST1813B
F.  Sealant - BMS 5-79 or 5-95 (Ref 20-30-41)
3.  Repair Upper Roller Guide Plate (65-29993-2) Latch Pin Hole (Fig. 801)
A.  Gain access to rework area by either removing upper roller guide plate from airplane or removing guide plate attach bolts and rotating plate sufficiently to accomplish rework.
B.  Using spotfacing fixture, spotface upper surface of guide plate at latch pin hole to a depth of approximately 0.080 inch and diameter of 0.593 inch.
C.  Fabricate 17-4PH stainless steel bushing with inside diameter of 0.3438 to 0.3478 inch and an outside diameter to allow an interference fit of 0.0015 to 0.0020 inch. Bushing thickness is to match spotface depth and to be flush with upper surface of guide plate and lower surface of channel surface. Heat treat bushing per standard industry practice to 900 °F for one hour and air cool.
D.  Install bushing in guide plate, finish reworked area to match existing finish and reinstall guide plate.
　
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