Instrument Panel Replacement; Rocker Panel Replacement; Cowl Replacement; Front Fascia 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.

Instrument Panel Replacement

Tool List
Electric/air Drill ............................................................ 1
Drill Bit, 7/32"............................................................... 1
Wrench, 5/16".............................................................. 1
Phillips Screwdriver ..................................................... 1
Rivet Gun .................................................................... 1
NOTICE
The instrument panel may be removed without removing the
cowl or may be removed as part of the cowl.
To prevent the possibility of injury due to lack of
vehicle information, the correct safety label
must be on the instrument panel at all times.
When installing a replacement instrument panel, a new
safety label (2) MUST be ordered and placed on the new
instrument panel. When ordering a replacement instru-
ment panel, provide vehicle serial number to the Service
Parts Representative who will provide the correct part
number for the safety label.
Using an insulated wrench, disconnect the battery cable
at the negative (-) battery terminal.
Pull the front of the floor mat (4) up to expose the rivets
(13) that secure the instrument panel (1) to the floor. Drill
out the rivets attaching the bottom of the instrument panel
to the floor and across the top of the instrument panel
attaching it to the cowl (12) (Ref. Fig. 2).
Remove the four ratchet fasteners (3) located within the
instrument panel storage compartments.
The instrument panel may now be pulled away from the
cowl.
Remove the drive rivets securing the key switch plate (10)
to the instrument panel. Rotate the key switch plate and
push it through the instrument panel opening, freeing the
panel for removal.
Reassembly is the reverse order of disassembly and will
require new drive rivets.

Cowl Replacement

Tool List
Electric/air Drill ........................................................... 1
Drill Bit, 7/32"............................................................... 1
Wrench, 5/16" ..............................................................1
Phillips Screwdriver .....................................................1
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Rivet Gun.....................................................................1
Duct Tape.....................................................................1
Allen Key, 3/16"............................................................1
Drill out the rivets (13) across the top of instrument panel
(1) attaching it to the cowl (12) (Ref. Fig. 2) and (Ref. Fig.
3).
Drill out the rivets (15) securing the sides of the cowl to
the frame.
Reassembly is the reverse order of disassembly and will
require new rivets.

Front Fascia Replacement

Tool List
Wrench, 7/16" ..............................................................1
Pry Bar.........................................................................1
The front fascia (139) need not be removed to replace
any other body components (Ref. Fig. 2).
If the front fascia is damaged, remove hardware (141)
securing the front shield to the frame.
Remove the two rivets (143) securing the front shield to
the brackets (144).
If a bracket is damaged, remove screw (145) securing it
to the frame after removing the front shield.
Install replacement shield in reverse order of
disassembly.

Rocker Panel Replacement

Tool List
Phillips Screwdriver .....................................................1
Wrench, 7/16" ..............................................................1
Electric/air Drill.............................................................1
Drill Bit, 7/32" ...............................................................1
Rivet Gun.....................................................................1
Remove the rocker panel (67) by removing the hardware
(70) securing them to the frame (Ref. Fig. 3). As the
rocker panel is removed, be sure to locate the three spac-
ers (73) under each sill plate for reuse when sill plates are
reinstalled.
To remove rocker panel end, remove rivet (75) and
unsnap rocker panel end from the vehicle frame. To
remove other the other end remove the hardware (68).
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(Ref. Fig. 2) and (Ref. Fig. 3).
Replace the rocker panel end in reverse order of disas-
sembly.
Repair and Service Manual
BODY
B
B
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