Front Seat Replacement; Rear Bumper Replacement - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Remove the screws (37) that secure seat back support to
the vehicle frame. Remove the hardware (38) that
secures the seat back support to the frame support (39).
Remove each seat back support and spacer (40) from
rear body. Repeat procedure on other seat back support.
At the front of the rear body, remove the rivets (44) secur-
ing the rear body to the frame and floorboard area. Drill
out the heads of the large head rivets (45) that secure the
bottom of the body panel to the side of the vehicle (Ref.
Fig. 3) and (Ref. Fig. 4).
Remove the rivets (43) that secure the floor of the bag-
well area to the frame underneath.
Remove the rear body.
If the trunk lid (46) is to be reused, remove the hardware
(47) securing the trunk lid to the body panel. Remove the
trunk lid.
Installation of rear body is in the reverse order of disas-
sembly using new rivets. Install the bolts (38) into the seat
supports (39) and tighten to 21 - 25 ft. lbs. (29 - 34 Nm)
torque.
Foot Rest Replacement
Tool List
Electric/air Drill ............................................................ 1
Drill Bit, 7/32"............................................................... 1
Socket, 9/16" ............................................................... 1
Ratchet ........................................................................ 1
Wrench, 9/16".............................................................. 1
The foot rest is heavy and awkward to handle.
To prevent possible personal injury, it is strongly
recommended that adequate help or a lifting
device be used to remove the foot rest from the
vehicle.
NOTICE
To avoid damage to the plastic body component, remove or
install seat support brackets by sliding to the open end of the
molded channel. Do not force the seat support brackets into or
out of the channels from above.
Remove rear valance panel (33) by prying out plastic fas-
teners (34) (Ref. Fig. 3) and (Ref. Fig. 4).
Remove the hardware (35) attaching rear option (cargo
bed or rear facing seat) to the seat back supports (36).
Remove the screws (37) that secure the seat back sup-
port to the vehicle frame. Remove the hardware (38) that
secures the seat back support to the frame support (39).
Remove each seat back support and spacer (40) from
rear body. Repeat procedure on other seat back support.
Remove the nut (41) securing the vertical foot rest
bracket (42) to each frame support (39) (Ref. Fig. 4).
(Leave the bolt in place.)
Remove the nut (43) securing the horizontal foot rest
bracket to each frame support. (Leave the bolt in place.)
While supporting the end of the foot rest, remove the bolt
attaching the vertical bracket to the frame support.
Replacement of the foot rest is the reverse order of
removal. Tighten bolts to 21 - 25 ft. lbs. torque.

Rear Bumper Replacement

Tool List
Electric/air Drill.............................................................1
Drill Bit, 7/32" ...............................................................1
Flat Tip Screwdriver .....................................................1
Allen Wrench, 7/32" .....................................................1
To remove the long bumper (49), remove the bolts (50) at
Qty.
each end of the rear bumper (Ref. Fig. 3).
To remove the short bumper (51), drill out rivets (52)
located at each end of the rear bumper (Ref. Fig. 3).
Carefully remove the plugs (53) with a screwdriver.
Remove the shoulder bolts (54) underneath the plugs.
Remove the rear bumper.
To replace the long bumper, engage the top of the bum-
per with the underside of the fenders. Push bumper
upward as fender slides between the bumper clips (55)
and the bumper. Insert bolts through holes in the bumper
into the frame and tighten to 9 - 12 ft. lbs. (12 - 16 Nm)
torque. Replace bumper plugs. Secure each end of the
bumper to the fender with bolt and J-nut (56).
To replace the short bumper, place the rear bumper
against the rear chassis and install new rivets on each
end of bumper. Insert bolts through holes in the bumper
into the frame and tighten to 9 - 12 ft. lbs. (12 - 16 Nm)
torque. Replace bumper plugs.

Front Seat Replacement

Tool List
Wrench, 7/16" ..............................................................2
Rachet .........................................................................1
Socket, 7/16" ...............................................................2
Torque Wrench ............................................................1
Repair and Service Manual
BODY
B
B
Qty.
Qty.
Page C-7