Body Component Replacement; Instrument Panel Replacement; Fig. 1 Drill Out Metal Rivet - E-Z-GO TXT FLEET Technician's Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to all 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 could gen-
erate sparks or repairs that require welding or
cutting.
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. Excessive pres-
sure 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 conventional
removable hardware (nuts, bolts, washers and screws).
Some components are mounted with 'pop' rivets 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 on Page C-1). Care must be exercised when drill-
ing to prevent the drill from being forced through the
plastic body components where it could damage com-
ponents 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 secur-
ing with hardware in the same orientation as removed.
The illustrations on the following pages indicate the
assembly methods for the various components.

Instrument Panel Replacement

Tool List
Electric/air drill .............................................................1
Drill bit, 7/32"................................................................1
Wrench, 5/16" ..............................................................1
Phillips screwdriver ......................................................1
Rivet gun......................................................................1
The instrument panel may be removed without removing the
cowl or may be removed as part of the cowl.
When installing a replacement instrument panel, a new
console safety label (4) MUST be ordered and placed
on the new instrument panel. When ordering a replace-
ment instrument panel, provide vehicle serial number to
the Service Parts Representative who will provide the
correct part number for the safety label.
Repair and Service Manual
Pop Rivet

Fig. 1 Drill Out Metal Rivet

NOTICE
BODY
Drill Out Rivet
Head Only
Qty.
Page C-1