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E.  Remove bolts from torque tube (2), connecting sleeves (18) and hinge pins (17). Slide connecting sleeves (18) away from hinges far enough to expose joints between torque tube (2) and hinge pins (17).
F.  Remove twelve housing attachment bolts (21) securing handle mechanism housing (3) to door structure.
G.  Remove four bolts (28) and washers (29) from exterior handle recess.
H.  Remove bolts securing splice plates (1) and (4) to door structure and remove splice plates.
I.  Disconnect upper and lower gate control rods (19) and (27) at their connection to each gate.
J.  Disconnect upper and lower gate control rods (19) and (27) through the access holes in the handle mechanism, from the gate operating crank (20). Move gate control rods (19) and (27) clear of handle mechanism.
500 
Oct 20/89  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  52-11-11 Page 401 

Door hinge Arm Installation  500 
52-11-11  Figure 401 (Sheet 1)  Oct 20/89 
Page 402 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

500  Door Hinge Arm Installation 
Oct 20/89  Figure 402 (Sheet 2)  52-11-11 
Page 403 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

Door Hinge Arm Installation  500 
52-11-11  Figure 401 (Sheet 3)  Aug 15/67 
Page 404 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

500  Door Hinge Arm Installation 
Aug 15/67  Figure 401 (Sheet 4)  52-11-11 
Page 405 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

K. Remove hinge pin bolts (12) and cover support brackets (13) from hinge arms (16).
NOTE:  The hinge pin bolts (12) can be reached from the outside of the door after the hinge covers are removed. The bolts can be turned by using a long 1/4-inch allen wrench which has the short arm length reduced to 0.5-inch.
L. Slide hinge pins (17) out of engagement with hinge arms (16) and remove hinge arms.
M. Remove handle mechanism housing (3) complete with torque tube crank (26) and torque tube
(2) from the door.
N. Remove and discard the exterior handle O-ring (30).

Door Hinge Arm Installation  500 
52-11-11  Figure 401 (Sheet 5)  Oct 20/89 
Page 406 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

500  Door Hinge Arm and Torque Tube Assembly 
Oct 20/89  Figure 402  52-11-11 
Page 407 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

4. Install Forward Entry Door Hinge Arms
A.  Examine the bushings (17) in the hinge fittings for wear, corrosion and fit.
B.  Check that O-rings (16, Fig. 402) are in good condition and are seated properly in the hinge pin grooves.
C.  Check that both floating nuts (14, Fig. 401) and their retainers (15) are positioned correctly in each hinge arm (16). Grease hinge pin bearing surfaces.
D.  Position each hinge arm (16, Fig. 401) in hinge support (11) in door structure, insert hinge pin
(17) through support bushing and hinge arm, and install hinge pin bolts (12) without fully tightening.
E.  Install a new exterior handle O-ring (30).
F.  Install handle mechanism housing (3) in door structure so that torque tube (2) lines up with hinge pins.
NOTE:  If endwise interference exists, adjust torque tube along its axis by manipulating the vertical adjustment nuts (24). Do not lock these nuts.
G.  Assemble the torque tube, hinge pins and sleeves.
(1)  
Move the sleeves (18) over the hinge pins (17).

(2)  
Put the bolts through the torque tube, sleeves and hinge pins.

(3)  
Tighten the nuts until they are at the end of the threads on the bolts.

NOTE:  The nuts do not tighten against the sleeve.

(4)  
Make sure there is no more than 0.016 inch between the sleeve and the washers.

(5)  
Install another washer if it is necessary to get the correct distance.

(6)  
Make any endwise adjustment of the torque tube by means of the vertical adjustment nuts (24).

NOTE:  These vertical adjustment nuts should be left finger-tight and unlocked because they will be used to obtain vertical adjustment of the door when it is installed in the airplane.
H.  Install four bolts (28) and washers (29) in the recess for the outside door handle.
　
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