Club Car CARRYALL 252 2007, Maintenance And Service Manual

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BODY AND TRIM Tilt Bed
4
NOTE: If installing a new front body, two 5/16-inch holes must be drilled after the body has been placed on the vehicle.
Use the body trim (13) as a guide for drilling the holes.
3. Tighten screws (18) holding front body trim against front body to 17 in-lb (1.9 N·m).
4. Vehicles equipped with headlights: Reconnect the light wiring harness to the headlight assemblies.
5. Vehicles equipped with a heavy-duty front bumper:
5.1. Install two carriage bolts (2) and lock nuts (3) from the heavy-duty front bumper support braces and install
bumper (1). Tighten bolts to 65 in-lb (7.3 N·m) (Figure 4-1, Page 4-4) .
5.2. Install two carriage bolts (5), spacers (4), and lock nuts (3) into heavy-duty bumper mounting positions
located on sides of front body (12). Tighten bolts to 65 in-lb (7.3 N·m).
6. Vehicles without heavy-duty bumper: Install two push type blind rivets (10) that secure lower front body to
frame (Figure 4-1, Page 4-4) .
7. Install front bumper onto vehicle and install screws (8) and lock nuts (9). Tighten to 65 in-lb (7.3 N·m).
TILT BED
See General Warning on page 1-1.
NOTE: Tilt bed removal and installation will be easier with a helper.
TILT BED REMOVAL
1. Raise bed and secure prop rod (17) in prop rod track (18). Hold bed securely in an upright position. Remove
cotter pin (23) and flat washer (22) from top end of prop rod where prop rod attaches to bed. Remove prop rod
(17) from bed and place prop rod between prop rod track (18) and rear body panel. Lower bed onto vehicle
frame
(Figure 4-2, Page 4-6) .
2. Remove two lock nuts (10) from left and right hinge assemblies (3 and 25).
3. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges, and remove the
hinge bolts (9) from the hinge assemblies.
4. Raise rear edge of bed approximately 6 inches (15.2 cm) and pull bed assembly toward rear of vehicle
approximately 3 inches (7.6 cm) to release bed latch assembly (2) from latch plate (1).
5. Lift bed from vehicle.
TILT BED INSTALLATION
1. Hold bed at a slight angle (front of bed lower than rear of bed) to vehicle and place front edge of bed onto vehicle
frame. Bed latches (5) should engage with latch plates (1)
(Figure 4-2, Page 4-6) .
2. Lower edge of bed onto vehicle and align hinge brackets (3) with bed hinge (25).
3. Start the bolts (9) into left and right hinge assemblies (3 and 25). It may be necessary to use an alignment tool to
align holes in hinge bracket with steel bushing in hinge assembly.
4. Use a small hammer to lightly tap bolts through hinge assembly.
5. Install a nylon lock nut (10) on each bolt (9) and tighten to 180 in-lb (21 N·m).
6. Lift bed and place the prop rod (17) in bed mounting hole. Install a 3/8-inch flat washer (22) and a new cotter pin
(23) on prop rod
(Figure 4-2, Page 4-6) .
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 4-5