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.
699322
Cowl Replacement
Tool List
Qty.
Electric/air drill ............................................................1
Drill bit, 7/32" ...............................................................1
Wrench, 5/16" ..............................................................1
Phillips screwdriver......................................................1
Pop Rivet Tool .............................................................1
Duct tape .....................................................................1
Allen key, 3/16" ............................................................1
1.
Drill out the rivets (6) across the top of instrument
panel (1) attaching it to the cowl (7) (Ref. Figure 1).
2.
Remove the rivet (11) at the front and back of each
rocker panel (14).
3.
Remove the rocker panel (14) by following the
4.
Drill out the rivets (17) securing the sides of the cowl
to the frame.
5.
From underneath the cowl, remove the ratchet fas-
tener (18) attaching the center of the splash panel
(19) to the frame cross member.
6.
Remove the four screws (8) located within the instru-
ment panel pockets.
7.
Remove the bolts and washers (20) from the sides of
the cowl and lift the cowl assembly from the vehicle.
8.
Reassembly is the reverse order of disassembly and
will require new rivets. The bolts and washers (20)
reinstalled into the cowl should be tightened to 8 - 12
ft. lbs.
Front Fascia Replacement
Tool List
Qty.
Wrench, 7/16" ..............................................................1
Pry bar ......................................................................... 1
1.
The front Fascia (22) need not to be removed to
replace any other body components (See Figure 1).
2.
If the front Fascia is damaged, remove hardware
(23) securing the front Fascia to frame.
3.
Remove the two rivets (24) securing the front Fascia
to the shield brackets (25).
4.
If the shield bracket (25) is damaged, remove bolts
(26) and nuts (27) securing it to the shield brace (28)
after removing the front Fascia (22).
5.
If the shield brace (28) is damaged, remove bolts
(29, 26) and nuts (27) securing it to the frame and
shield bracket (25) after removing the front Fascia
(22).
6.
Install replacement front Fascia in reverse order of
disassembly.
Rocker Panel Replacement
Tool List
Qty.
Phillips screwdriver ......................................................1
Wrench, 7/16" ..............................................................1
Electric/Air drill .............................................................1
Drill bit, 7/32"................................................................1
Pop Rivet Tool..............................................................1
1.
Remove the rocker panel with sill plates (14, 55) by
removing the hardware (15) securing them to the
2.
As the rocker panel is removed, be sure to catch the
spacers (16) under each rocker panel for reuse when
rocker panels are reinstalled.
3.
To remove the rocker panel, remove the rivets (11) at
the front and rear of the rocker panel (14). Unsnap
the rocker panel (14) from the vehicle frame.
4.
Replace rocker panel in reverse order of disassem-
bly.
5.
Align the replacement rocker panel with spacers in
place and install hardware.
Body Replacement
Tool List
Qty.
Electric/air drill .............................................................1
Drill bit, 7/32"................................................................1
Socket, 3/8"..................................................................1
Socket, 7/16"................................................................1
Socket, 9/16", deepwell ...............................................1
Ratchet, 3/8" drive .......................................................1
Wrench, 3/8" ................................................................1
Wrench, 7/16" ..............................................................1
Wrench, 9/16" ..............................................................1
Pop Rivet Tool..............................................................1
Phillips screwdriver ......................................................1
Pry bar .........................................................................1
NOTICE: Prior to removing the rear body, the foot
rest, must be removed. See the applicable para-
graphs for instructions for replacement of those
items.
1.
Remove the rocker panels as described above.
2.
Remove seat from body (27) (Ref. Figure 2).
To prevent possible injury or death
from battery explosion, batteries
should always be removed before
any servicing that could generate 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 pressure could result in the drill bit
being forced through the body panel and penetrat-
