Body Replacement; Shuttle 2+2 Component Replacement - Ezgo 605586 Repair And Service Manual

BODY
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B

Body Replacement

Tool List
Electric/air drill ............................................................ 1
Drill bit, 7/32" ............................................................... 1
Socket, 3/8" ................................................................. 1
Socket, 7/16" ............................................................... 1
Socket, 9/16", deepwell, 3/8" drive .............................. 1
Ratchet, 3/8" drive ....................................................... 1
Wrench, 3/8" ................................................................ 1
Wrench, 7/16" .............................................................. 1
Wrench, 9/16" .............................................................. 1
Rivet gun ..................................................................... 1
Phillips screwdriver...................................................... 1
Pry bar ......................................................................... 1
Prior to removing the rear body, the foot rest or cargo bed, as
applicable, must be removed. See the applicable paragraphs
for instructions for replacement of those items.
Remove the rocker panels as described above.
Remove seat from body (27) (Ref. Fig. 3 on Page C-3).
To prevent possible injury or death from bat-
tery explosion, batteries should always be
removed before any servicing that could gen-
erate sparks or repairs that require welding or
cutting.
It is important to use a sharp drill bit when
removing the rivets on the side of the vehicle.
Extreme care must be used when drilling out
the rivets located in the front of the body and
the bottom side of the body. Excessive pres-
sure could result in the drill bit being forced
through the body panel and penetrating a bat-
tery. As extra protection, it is recommended
that a protective piece of sheet metal be
placed between the battery and the rivet. Use
of a drill depth stop will provide additional pro-
tection.
Remove hardware (28) attaching seat back supports
(29) to body.
At the front of the rear body, remove the rivets (30)
securing the rear body to the frame and floorboard area.
Drill out the heads of the large head rivets (31) that
secure the bottom of the body panel to the side of the
vehicle.
Page C-6
Remove the rivets (32) that secure the floor of the bag-
well area to the frame underneath.
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Remove the body.
If the trunk lid (33) is to be reused, remove the hardware
(34) 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 (28) into the
seat supports (29) and tighten to 21 - 25 ft. lbs.

Shuttle 2+2 Component Replacement

Tool List
Electric/air drill ............................................................1
Drill bit, 7/32"................................................................1
Socket, 9/16", 3/8" drive ..............................................1
Ratchet, 3/8" drive .......................................................1
Wrench, 9/16" ..............................................................1
Remove rear valance panel (36) by prying out plastic
fasteners (37) (Ref. Fig. 4 on Page C-4).
Remove the hardware (38) attaching rear facing seat
(39) to the seat back supports (40).
Remove the screws (41) that secure seat back support
to vehicle frame. Remove the hardware 42) that secures
seat back support to frame support (43). Remove each
seat back support and spacer (44) from the rear body.
Repeat procedure on other seat back support.
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 the hardware (45) securing the vertical foot rest
bracket (46) to each frame support (43) (Ref. Fig. 4 on
Page C-4). (Leave the bolt in place.)
Remove the nut (47) 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.
Repair and Service Manual
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