Front Body Removal; Front Fender Removal; Front Fender Installation; Front Body Installation - Club Car TURF 272 2005 Maintenance Service Manual

4
BODY AND TRIM

FRONT BODY REMOVAL

1. Remove five caps (1) from top of dashboard (2) (Figure 4-2, Page 4-5).
2. Use a Torx #T-30 driver to remove the Torx-head screws (3) and washers (4) from top of front body (6).
3. Use a 5/16 nut driver to remove five screws (5) from underside of dashboard (2) and gently slide dash-
board away from front body (6).
4. Use a phillips head screwdriver to remove the six Tuflok fasteners (7) from sides and two (7) from front
of front body (6).
5. Disconnect lighting wiring harness from each headlight assembly.
6. Lift the back edge of the body up and pull forward to remove from vehicle (Figure 4-2, Page 4-5).

FRONT FENDER REMOVAL

1. Remove front body (6) (Figure 4-2, Page 4-5). See Front Body Removal on page 4-4.
2. Pull back floor mat to access rivets securing front fender (9) to frame. Drill out two 3/16 x 5/8 pop rivets
(10) and remove two washers (11).
3. Use a 3/8 hex-head socket to remove two screws (12) from fender frame support and remove fender.

FRONT FENDER INSTALLATION

1. Reverse the fender removal process (Figure 4-2, Page 4-5).
2. Tighten screws (12) to 50 in-lb (5.7 N·m).
3. Pop rivet fender to frame using two 3/16 x 5/8 pop rivets (10) and two 3/16 rivet washers (11).
4. Install front body. See Front Body Installation on page 4-4.

FRONT BODY INSTALLATION

1. Reverse the front body (6) removal process (Figure 4-2, Page 4-5).
2. Secure front body (6) to dashboard (2) with screws (3) and plastic washers (4) and tighten to 45 in-lb (5.1
N·m).
3. Install five caps (1).
4. Secure front body (6) to fenders (9) with fasteners (7) and push the heads in until they snap into place.

SEAT

Read General Warning, Section 1, Page 1-1.
Clean seats regularly using the following guidelines: See following CAUTION.
CAUT ION
• To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the
seat from the vehicle first.
Page 4-4 2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Seat