General; Body Component Replacement - Cushman 632904 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
BODY
NOTICE
In the following text, there are references to removing/install-
ing bolts etc. Additional hardware (nuts, washers etc.) that are
removed must always be installed in their original positions
unless otherwise specified. Non-specified torques are as
shown in the table in Section A.

General

To prevent possible injury or death from bat-
tery explosion. Batteries should always be
removed before any servicing that will gener-
ate sparks. 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. Exces-
sive pressure could result in the drill bit being
forced through the body panel and penetrating
a component. As extra protection, it is recom-
mended that a protective piece of sheet metal
be placed between the battery and the rivet.
Use of a drill depth stop will provide additional
protection.
In general, body component replacement can be
accomplished with a minimum of specialized tools.
Most body components are held in place with conven-
tional removable hardware (nuts, bolts, washers and
screws). Some components are mounted with 'pop' riv-
ets which require that the rivet head be removed in
order to push out the shank of the rivet. The rivet head
is easily removed by drilling into the head with a sharp
drill bit that is slightly larger than the shank of the rivet
(Ref. Fig. 1). Care must be exercised when drilling to
prevent the drill from being forced through and damag-
ing components where it could damage components
located immediately behind the rivet. The best way to
prevent this from occurring is to use a sharp drill bit that
requires very little pressure to cut successfully and to
place a piece of protective sheet metal between the
surface being drilled and components directly behind it.

BODY COMPONENT REPLACEMENT

The body components can be replaced by removing the
securing hardware, replacing the component and
securing with hardware in the same orientation as
removed. The illustrations on the following pages indi-
cate the assembly methods for the various compo-
nents.
Repair and Service Manual
Drill Out Rivet
Pop Rivet
Head Only
Fig. 1 Drill Out Metal Rivet
B
BODY
B
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