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 (5)  S 434-068-B00Connect the hinge arms to the door as follows: (a) Examine the hinge attach bolts and the nuts before you install the door. (b) If the bolt threads show signs of bottoming out, the nut must be examined for damaged thread and replaced if it is necessary.
 NOTE:____ Changes in the shim thickness between the hinge fitting and the door necessitate selective bolt length dependent on the quantity of stackup. Use of the proper length bolts ensure the integrity of the hinge attachment.

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 (c)  Install the shims between the hinge arms and the door.
 NOTE: Use the shims from the removal task.
____
 (d)  
Connect the hinge arm to the door with the bolts (2).

 (e)  
Make sure the bolts are not loose.

 1)  If the bolt is loose, make sure it has the correct grip length.

 (f)
Make sure the bolts hold the hinge arm tightly to the door.

 1)  If the bolt does not fully engage the locking feature of the nut, install a longer bolt.
 S 434-069-B00
 (6)  Attach the snubber (Fig. 401):
 WARNING: ALWAYS USE A DOOR SUPPORT BRACE THAT HAS A RED COLOR TO
_______ KEEP THE DOOR OPEN WHEN THE BALANCE MECHANISM AND SNUBBER ARE DISCONNECTED. THIS WILL HELP PREVENT INJURY TO PERSONS NEAR THE DOOR.
 (a)  
Put the door in position on the door support brace.

 (b)  
Install the bolt (1) to attach the snubber to the door bracket.

 (c)  
Make sure the snubber keeps the door in the open position.

 S 434-017-B00
 (7)  
Connect the balance mechanism cable as follows (Fig. 402):

 (a)  
Make sure there is a nut and washer on the counterbalance shaft against the adjustment fitting to hold the spring and stop counterblance operation.

 (b)  
Open the cargo door 1-2 inches.

 (c)  
Install a block under the lower stops to hold the cargo door up.

 (d)  
Make sure the balance mechanism cable is loose.

 (e)  
Make sure the cable has the correct routing from the
 counterbalance mechanism to the floor beam.

 

 WARNING: MAKE SURE THERE IS NO TENSION ON THE BALANCE MECHANISM
_______ CABLE. THE CABLE CAN RETRACT ACCIDENTALLY AND CAUSE INJURY IF IT IS TIGHT.
 (f) Connect the door balance mechanism cable to the floor beam:
 1)  Apply BMS3-24 grease and install the pin, washer and a new cotter pin to attach the sheave to the bracket.
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737-300/400/500MAINTENANCE MANUAL
 2)  Apply BMS3-24 grease and install the alignment bolt and retainer ring.
 3)  Make sure the distance between the forward edge of the sheave and the forward edge of the bracket is the same as the one that was measured before.
 4)  Install lockwire on the alignment bolt.
 (g)  
Close and latch the door.

 (h)  
Make sure there is tension in the counterbalance cable.

 (i)  
Remove the nut and washer on the counterbalance guide pin.

 S 824-071-B00
 (8)
Do the task to adjust the balance mechanism (Ref. 52-31-12/401).

 S 434-020-B00

 (9)
Connect the lanyard assembly between the door and the floor beam.

 TASK 52-31-00-404-022-B00
 4.  Cargo Compartment Door Installation (new door or not the initial door)___________________________________
 A.  Standard Tools and Equipment
 (1)  
Door support brace - 2 x 4 inch wood painted red of applicable length to keep the door in the open position

 (2)  
Nut - BACN10YR6CD

 (3)  
Washer - AN960C616

 B.  
Consumable Materials
　
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