Foot Rest Replacement; Rear Bumper Replacement; Front Seat 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.
rear body. Repeat procedure on other seat back sup-
port.
At the front of the rear body, remove the rivets (44)
securing 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 hard-
ware (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
fasteners (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
Qty.
To remove the bumper (49), remove the bolts (50) 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 bumper, engage the top of the bumper
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).

Front Seat Replacement

Tool List
Wrench, 7/16".............................................................. 2
Rachet ......................................................................... 1
Socket, 7/16" ............................................................... 2
Torque Wrench ............................................................ 1
Refer to TORQUE SPECIFICATIONS in Section A for stan-
dard torque values unless otherwise noted in manual text.
The front seat bottom is not held in place by hardware
(Ref. Fig. 3), Rather, it is nestled into the top of the front
seat pod. To remove the seat, simply lift the seat off the
pod.
Repair and Service Manual
BODY
NOTICE
Page D-7
B
B
Qty.
Qty.