BODY AND TRIM
Front Body – 850
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 4-7
4
BUMPER/BRUSH GUARD (HEAVY DUTY) REMOVAL
1. Remove bolts (4) and lock nuts (5)
(Figure 4-4, Page 4-6)
.
2. Remove screws (6) and pull the heavy duty bumper/brush guard (3) from vehicle.
See following WARN-
ING.
ý
WARNING
• Have another person hold brush guard firmly against the frame when removing the last bolt.
The brush guard weighs approximately 40 pounds. Hold the brush guard securely during
removal to avoid personal injury.
• Do not operate the vehicle without an installed front bumper and brush guard that are
specifically designed and approved for use on this vehicle. Instability in the vehicle could
cause serious injury or death.
BUMPER/BRUSH GUARD (HEAVY DUTY) INSTALLATION
1. Position the heavy duty bumper/brush guard (3) against body and front frame and loosely install top bolts
(4) and lock nuts (5)
(Figure 4-4, Page 4-6)
.
See preceding WARNING.
2. Install bottom screws (6) and tighten to 14 ft-lb (19 N·m).
3. Tighten lock nuts (5) to 17.5 ft-lb (24 N·m).
FRONT REMOVAL
1. Remove bumper/brush guard.
See Bumper/Brush Guard (Standard) Removal on page 4-5 or
Bumper/Brush Guard (Heavy Duty) Removal on page 4-7.
2. Remove caps (1) from screws (2)
(Figure 4-5, Page 4-8)
.
3. Remove screws (2) and plastic scalloped washers (3) securing the dash trim strip (4) and front body (5).
4. Remove covers (6 and 7) and plastic rivets (8) from each side of front body.
5. Disconnect wire harness from headlights and remove front body from vehicle.
FRONT BODY INSTALLATION
1. Position front body (5) onto frame and connect wire harness to headlights.
2. Align front body (5) and dash trim strip (4) holes with holes in frame and install the five screws (2) and
scalloped washers (3). Tighten to screws to 45 in-lb (5 N·m). Attach plastic caps (1) onto screws (2).
3. Secure each side of front body to frame with plastic rivets (8).
4. Install body covers (6) and (7)
(Figure 4-5, Page 4-8)
.
5. Install plastic screws (5) on the sides of the dash and body.
6. Install bumper and brush guard.
See Bumper/Brush Guard (Standard) Installation on page 4-6 or
Bumper/Brush Guard (Heavy Duty) Installation on page 4-7.
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