[hharney]

Has someone re-rigged the flaps recently, per the service manual? I have seen where service has been performed on the system and the rigging is not completed correctly. Setting up the indicator on the panel is really tricky and can be difficult at best. If the flap cable were changed or cables released for flap panel removal this could be the reason.

Go to the SM and follow the very tedious sequence of adjustments and rigging. It can take a good day or two to get it right. Checking the degree of deflection at each setting is a good place to start to determine if it is out of rig.