Rear Valence Panel Removal; Side Panel Removal; Load Deck Removal - 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.
Drill out the two rivets (1) securing the fuse block (2) to
the fender (3) (Ref. Fig. 7).
Loosen the rear wheel lug nuts approximately 1/4 turn
and lift the rear of the vehicle and support on jack stand
per SAFETY section. Remove the wheel and tire. Firmly
grasp the rear of the rivet (39) and drill out the two rivets
securing the fender (41).
Gently pry out the ratchet (Christmas tree) fasteners (38)
and remove fender (41).
Reassembly is the reverse of disassembly. New Ratchet
fasteners (38) may be required. New rivets are required
to attach the fuse block to the fender.

Rear Valence Panel Removal

Tool List
Small Pry Bar .............................................................. 1
Gently pry out the two ratchet (Christmas tree) fasteners
(1) and remove the rear valence panel (2) from the frame
.(Ref, Fig. 8).
Fig. 8 Rear Valence Panel Removal
Reassembly is the reverse of disassembly and requires
the use of new ratchet fasteners.

Side Panel Removal

Tool List
3/8" Drill ....................................................................... 1
3/16" Drill Bit................................................................ 1
Rivet Gun .................................................................... 1
Drill out the two horizontal rivets (1) at the rear of the side
panel (2) remove the rivets and note the location of the
two washers (3) (Ref. Fig. 9).
Qty.
Reassembly is the reverse of disassembly and requires
2
the use of new rivets.

Load Deck Removal

Tool List
Torque Wrench, ft. lbs..................................................1
Phillips Screwdriver Bit ................................................1
Ratchet ........................................................................1
1
Socket, 7/16" ...............................................................1
Wrench, 7/16" ..............................................................1
For ease of handling, separating the two sections of the load
bed is recommended.
Qty.
Remove the four screws (1) from the movable (2) side of
the load bed hinges (3). Remove the movable deck (Ref.
Fig. 10).
Remove the four screws, washers and lock nuts (4, 5 & 6)
securing the load bed (2) to the bed frame (7). Remove
the load bed.
Reassembly is the reverse of disassembly. Nuts (6)
securing the load bed (2) to the bed frame (7) are to be
tightened to 8.5 - 9.0 ft. lbs. (11.5 -12 Nm) torque. It is rec-
ommended that new lock nuts be used.
Repair and Service Manual
3
Fig. 9 Side Panel Removal
NOTICE
BODY
B
B
2
1
Qty.
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