Front Seat Pod Replacement; Rear Body Replacement - Cushman Shuttle 2 Service Manual

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

Front Seat Pod Replacement

Tool List
Wrench, 7/16" .............................................................. 2
Wrench, 1/2" ................................................................ 2
Wrench, 9/16" .............................................................. 2
Phillips Screwdriver ..................................................... 1
Drill .............................................................................. 1
Drill Bit, 3/16" ............................................................... 1
Drill Bit, 5/16" ............................................................... 1
Rivet Gun..................................................................... 1
Ratchet ........................................................................ 1
Socket, 7/16" ............................................................... 2
Socket, 1/2" ................................................................. 2
Socket, 9/16" ............................................................... 2
Torque Wrench ............................................................ 1
Refer to TORQUE SPECIFICATIONS in Section A for standard
torque values unless otherwise noted in manual text.
To reduce the danger of battery explosion,
disconnect the negative (-) battery cable
before proceeding.
To gain access to the inside of the seat pod (18), lift the
front seat bottom vertically from its positioning pins (Ref.
Fig. 3). Remove the hardware attaching the seat back
supports and remove the supports from pod.
Disconnect the four-pin connector from the Speed control
at connection near the floor.
Remove the hardware (26) securing the seat pod to the
floor and remove the pod.
Installation of new seat pod is the reverse order of disas-
sembly using new rivets.

Rear Body Replacement

Tool List
Electric/air Drill ............................................................ 1
Drill Bit, 7/32" ............................................................... 1
Socket, 3/8" ................................................................. 1
Socket, 1/2" ................................................................. 1
Socket, 9/16", Deepwell .............................................. 1
Page C-6
NOTICE
Repair and Service Manual
Ratchet, 3/8" Drive.......................................................1
Wrench, 3/8" ................................................................1
Qty.
Wrench, 1/2" ................................................................1
Wrench, 9/16" ..............................................................1
Rivet Gun .....................................................................1
Phillips Screwdriver......................................................1
Pry Bar .........................................................................1
Torque Wrench.............................................................1
Refer to TORQUE SPECIFICATIONS in Section A for standard
torque values unless otherwise noted in manual text.
To prevent possible injury or death from battery
explosion. The battery should always be
removed before any servicing that will generate
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 drill-
ing out the rivets located in the front of the body
and the bottom side of the body. Excessive
pressure could result in the drill bit being forced
through the body panel and penetrating the 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 protection.
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.
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
Qty.
out of the channels from above.
Remove the rear rocker panel as described above.
Remove the rear seat from the rear body (32) (Ref. Fig.
3).
Remove the hardware (35) attaching rear option (cargo
bed or rear facing seat) to the seat back supports (36).
NOTICE
NOTICE
NOTICE