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E.  Disconnect hydraulic lines from flap hydraulic motor.
CAUTION: BE PREPARED TO CATCH HYDRAULIC FLUID.
F.  Install plugs in hydraulic lines and cap all ports.
G.  Relieve tension in WFFA and WFFB cables and detach cables from power unit. Tag cables to aid in reinstallation.
H.  Disconnect bonding jumper from power unit mounting bracket.
I.  Remove power unit mounting bolts and remove power unit from airplane.
J.  Remove three mounting bolts and separate flap alternate drive unit from power unit.
K.  Remove four mounting bolts and separate hydraulic motor from power unit.
4.  Prepare Flap Power Unit for Installation
A.  Apply light film of grease to full length of output splines on flap hydraulic motor and on flap alternate drive unit.
B.  Install flap hydraulic motor on power unit. Secure with four mounting bolts (Fig. 401).
C.  Install flap alternate drive unit on power unit. Secure with three mounting bolts.
5.  Install Flap Power Unit
A.  Position power unit on support bracket and install power unit mounting bolts (Fig. 401).
B.  Install bonding jumper between flap alternate unit and mounting bracket.
C.  Rotate power unit output shafts to align mark on drum within 0.03 inch with matching mark on power unit housing.

535 
Oct 20/87  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  27-51-222 Page 405 

D.  Remove plugs from hydraulic lines and caps from hydraulic motor ports.
E.  Connect hydraulic lines to hydraulic motor.
F.  Check that rigging pin F-1 is installed in flap control unit (Fig. 402).
G.  Connect WFFA and WFFB cables to power unit follow-up drum on aft side of power unit. Pay particular attention to cable routing as shown in Fig. 401 to avoid incorrect routing. Wrap approximately 2-1/4 turns of WFFA cable on follow-up drum and approximately 1/3 turn of WFFB cable on follow-up drum.
NOTE:  At flap control unit WFFA, cable will have approximately 1-1/2 turns and WFFB cable will have approximately 2-1/2 turns on follow-up drum.
H.  Adjust turnbuckles to tension cables as shown in following table. When cables are tensioned, ensure that rigging pin fits freely in control unit. Install locking clips on turnbuckles.
TEMPERATURE (°F)  CABLE RIGGING LOAD (+20/-0 POUNDS) *[1] 
110 90 70 50 30 10 -10 -30 -40  71 65 60 55 49 44 38 33 30 

*[1]  For required periodic checks without system discrepancy reports, the cable tensions may deviate +20/-20 pounds from Table values. For cable tension checks resulting from system discrepancy reports, the tensions may deviate +20/-0 pounds from Table values. Whenever cables are readjusted, Table values must be met.
NOTE:  Allow a minimum of 1 hour at constant ambient temperature (+ 5°F) for airframe temperature to stabilize.
I.  Rotate torque tubes which connect to power unit until angular clearance between upstops on flap transmissions are 170 to 190 degrees (1/2 turn +10 degrees) turn from contact (Fig. 403).
CAUTION:  MAXIMUM ALLOWABLE ANGULAR CLEARANCE IS 1/4 TO 5/6 TURN. A VALUE FOR (XL) OUTSIDE THIS RANGE MAY CAUSE DAMAGE DURING FLAP OPERATION. PREVIOUS LATERAL TRIM CORRECTIONS SHOULD BE RETAINED.
J.  Lubricate torque tube sleeves with grease and connect to power unit spline couplings. Install retaining screws and lockwire.
K.  Remove rigging pin F-1 from flap control unit (Fig. 402).
27-51-222 Oct 20/87 Page 406
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.

G25821
Flap Transmission Upstop Clearance 
535  Figure 403 
May 15/72  27-51-222 
Page 407 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

L. On circuit breaker panel P6 , close TE ALT FLAP DRIVE MOTOR circuit breaker.
M. Test flap power unit (Ref 27-51-221, Adjustment/Test).
N. Check hydraulic reservoir and service if required (Ref Chapter 12, Hydraulic Servicing).
O. Install inboard flap track fairings (Ref 27-51-141, Inboard Flap Track Fairings).
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FLAP HYDRAULIC MOTOR - REMOVAL/INSTALLATION
Equipment and Materials
A.  Fire Resistant Hydraulic Fluid - BMS 3-11
B.  Skydrol Assembly Lube - MCS 352
C.  Grease - MIL-G-23827
2.  Remove Flap Hydraulic Motor
A.  Remove system A hydraulic power and depressurize hydraulic reservoir A. Refer to 27-51-0, Trailing Edge Flaps - Maintenance Practices.
B.  Disconnect hydraulic lines from hydraulic motor. (See figure 401.)
　
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