B
16
Repair and Service Manual
BODY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
653045
Front Bumper Replacement
Tool List
Quantity
Drill .............................................................................. 1
Drill Bit ......................................................................... 1
Punch, Small ...............................................................1
Pop Rivet Tool .............................................................1
Hammer....................................................................... 1
NOTICE: The cowl (2) can be removed along with
the front fenders.
Remove the brush guard, See Brush Guard Replace-
ment.
Remove two bolts (17) and washers (18) from the front
bumper (16). Then remove the two bolts (21) and nuts
(23) from mounting bracket (22) (Figure 7).
Leave rivets (20) in place, do not remove bracket (22).
Remove the bumper (16) from the vehicle.
Figure 7 Front Bumper Replacement
To replace the front bumper (16) with new assembly, drill
out the rivets (20) securing the front bumper (16) to the
mounting bracket (22).
Assemble front bumper (16) in reverse order of removal.
Tighten the bolts (17) to the torque value specified below.
Rocker Panel Replacement
Tool List
Quantity
Phillips Screwdriver......................................................1
Socket, 3/8”..................................................................1
Ratchet.........................................................................1
Torque Wrench, in. lbs .................................................1
Remove two screws (15), spacers (16) and nuts (17) from
top portion of rocker panel (19). Retain hardware for later
installation (Figure 8).
Drill out the rivets (18) that secure the rocker panel to the
vehicle frame. Remove rocker panel (19).
Repeat the steps for the other side of vehicle if necessary.
Assemble rocker panel in the reverse order of removal
using new rivets (18).
Tighten nuts (17) to the torque values specified below.
Figure 8 Rocker Panel
Side Panel Replacement
Tool List
Quantity
Drill...............................................................................1
Drill Bit..........................................................................1
Socket, 7/16”................................................................1
Wrench, 7/16” ..............................................................1
Pop Rivet Tool..............................................................1
Torque Wrench, ft. lbs ..................................................1
To replace either driver or passenger side panel, first
remove rocker panels. See Rocker Panel Replacement.
Remove two ratchet rivets (24) securing side panel (22) to
Item
Torque Specification
17
6 - 8 ft. lbs. (8.5 - 10.5 Nm)
Front of Vehicle
17 18
16
20
21
22
23
19
24
Item
Torque Specification
17
45 - 55 in. lbs. (5 - 6 Nm)
18
15
19
16
17
18
Front of Vehicle
Property of American Airlines
