B
BODY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
23
Repair and Service Manual
10002660
BODY
GENERAL
NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise
specified. If torque values are not specified, refer to
the Torque Specifications (See TORQUE SPECIFI-
CATIONS on page 5).
To prevent possible injury or death
from battery explosion, batteries
should always be removed before
any service is performed that may
generate sparks.
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 pressure could result in the drill bit
being forced through the body panel and penetrat-
ing a component behind it. It is recommended that
extra protection be provided by using a protective
piece of sheet metal placed between the battery and
the rivet. Use of a drill depth stop will provide addi-
tional protection.
Body components can be replaced with a minimum of
special tools. Most body components are held in position
with standard removable hardware (nuts, bolts, washers
and screws). Some components are installed with pop riv-
ets that require the rivet head be removed to push the
shank of the rivet out. The rivet head can be removed by
drilling into the head with a sharp drill bit that is slightly
larger than the shank of the rivet (Ref. Fig. 1). Do not
allow the drill bit to push through and damage compo-
nents behind the rivet. Use a sharp drill bit that needs
minimum pressure to correctly cut, and put a piece of pro-
tective sheet metal between the panel and components
behind the panel.
BODY COMPONENT REPLACEMENT
NOTICE: Most mechanical and electrical compo-
nents are accessible without removing body panels
from the vehicle.
To replace the body components, remove the mounting
hardware, replace the component and secure with hard-
ware in the original position.
The following illustrations indicate the rivet removal meth-
ods for the different components. (Ref. Fig. 1) (Ref. Fig.
Fig. 1 Drill Out Metal Rivet
Fig. 2 Drive Rivet Removal
Fig. 3 Remove Ratchet Fasteners
Pop Rivet
Drill out rivet
head only
Push pin with
screwdriver
from rear side
Drive pin through
with punch from
front
OR
Ratchet
Fastener
Remove fastener
with pry bar
