Utilimaster REACH Service Manual Download

Page: 172 / 198

Utilimaster Corporation attempts to provide

information that is accurate, complete, and

useful. All information contained in this

manual is based on the latest product infor-

mation available at the time of publication.

However, because of the Utilimaster policy

of continual product improvement, Utilimas-

ter reserves the right to amend the informa-

tion in this document at any time without

prior notice.

This material is confidential and the prop

erty of Utilimaster. It is shared with your

company for the sole purpose of helping you

with the operation of the described equip-

ment.

Utilimaster makes no warranty of any kind

with regard to this material, including, but

not limited to, the implied warranties of

merchantability and fitness for a particular

purpose. Utilimaster shall not be liable for

errors contained herein or for incidental or

consequential damages in connection with

the furnishing, performance, or use of this

material.

Utilimaster expressly disclaims all respon-

sibility and liability for the installation, use,

performance, maintenance, and support of

third-party products. Customers are advised

to make their independent evaluation of such

products.

No part of this document may be photo-

copied, reproduced, or translated to another

language without the prior written consent

of Utilimaster.

Utilimaster Corporation attempts to provide

information that is accurate, complete, and

For Assistance Call: 800-237-7806

Visit us at:

www.utilimaster.com

172

Reach—Body Service Manual

E-mail:

[email protected]

Fastener Replacement

BOM

Fastener

Removal

Use a die grinder to cut off the BOM fastener. Use a center punch to

knock out the center pin. The remaining ring may need to be drilled

out.

Replacement

A BOM

fastener should be replaced per original specifications. However, in some applications

it may be able to be replaced with a Grade 8 bolt and a Grade 8 locknut of like diameter. If

replacing with a nut and bolt, always remember to use flat washers against all aluminum surfaces.

Blind Rivet

NOTE: Includes MONOBOLT

, Magna-Bulb

Magna-loc

, Hemlock

,and POP

rivets.

Removal

1. Use a center punch (or an air hammer with a punch

attachment) to knock the stem out of the fastener.

Drill off the head of the blind rivet using a #11 (or 3/16" [5

mm]) or F (or 1/4" [6 mm]) drill bit (depending on blind

rivet size). The back stem should fall off.

NOTE: Be very careful not to enlarge the hole while drilling

off the head. If the hole does become enlarged,

you will need to put a larger fastener in its place.

3. Use a center punch to knock out the center pin.

Replacement

Use a rivet gun to replace it.

Channel Nut

Removal

Use a small screwdriver to turn the channel nut 90°.

Replacement

Insert channel nut horizontally and turn 90°.

BOM fastener

Magna-Bulb

Magna-lok

POP rivet

Channel nut

Summary of Contents for REACH

Page 1: ...not limited to the implied warranties of merchantability and fitness for a particular purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of thi...

Page 2: ...the instructions in this document for safe and optimal operation and maintenance of this vehicle This manual contains drawings and photos to aid in servicing the vehicle and it may include maintenance information on some items installed but not manufactured by Utilimaster Corporation Items such as chassis and drive train components or certain interior furnishings may be covered by separate manufac...

Page 3: ...ty and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete a...

Page 4: ...terial Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation att...

Page 5: ...or the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 5 For Assistanc...

Page 6: ...limaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to p...

Page 7: ...allation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 7 For Assistance Call 800 ...

Page 8: ...rformance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us...

Page 9: ...nformation that will help you complete the procedure CAUTIONS warn against making an error that could damage the vehicle WARNINGS remind you to be careful when there is risk of personal injury Below are some basic WARNINGS that you should heed when you work on the vehicle s body They are not all inclusive and common sense must be used when servicing vehicles Always read and understand all instruct...

Page 10: ...For Assistance Call 800 237 7806 Visit us at www utilimaster com 10 Reach Body Service Manual E mail custsvc utilimaster com Vehicle orientation Before You Go Inspection Checklist Before driving inspect the following Visually inspect the tires for possible underinflation or damage Test tire inflation pressure with a quality pressure gauge at least weekly Check wheels for cracks damage or any missi...

Page 11: ...Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts t...

Page 12: ... and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and Figure LA 15 Federal Certification Label For Assistance Call 8...

Page 13: ...ocument may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 13 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Service Procedures Batteries Access NOTE The access panel for the batte...

Page 14: ...h Unlike painted surfaces superficial damage to the gelcoat can often be buffed out to its original finish Dents and deep scratches can be covered by applying a layer of gelcoat that is sanded and buffed back to its finished look Adding the color of the original body to the gelcoat before application eliminates need for paint Minor Repair Damage that penetrates the composite glass reinforced subst...

Page 15: ...eir independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 15 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 5 Inspect ...

Page 16: ...urate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 16 Reach Body Service Manual E mail custsvc utilimaster com Minor Composite Repair Minor repair is necessary with damage that penetrates the composite glass reinforced substructure that does NOT go through to the other side OR holes no larger than a golf ball 1 Remove any decals or body graphics in the repair area ...

Page 17: ... the composite glass reinforced substructure is larger than a golf ball 1 Remove any decals or body graphics in the repair area 2 Remove anything mounted inside the vehicle that would be affected by the repair process 3 Measure the damaged area and use a straight edge and square to cut out a replacement plug from a new panel The plug should be at least 1 larger than the damaged area on all sides 4...

Page 18: ...use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Vi...

Page 19: ...n sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate co...

Page 20: ...mance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Util...

Page 21: ...es in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without th...

Page 22: ...ion with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior writt...

Page 23: ...rformance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster ...

Page 24: ...hing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utili...

Page 25: ...ility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complet...

Page 26: ...ndent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 26 Reach Body Service Manual E mail custsvc utilimaster com Cladding Front F...

Page 27: ...ndent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 27 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Rear There are five ...

Page 28: ...ndependent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 28 Reach Body Service Manual E mail custsvc utilimaster com Upper Post ...

Page 29: ...independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 29 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Kickplate Remo...

Page 30: ...erformance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster...

Page 31: ...ntial damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language...

Page 32: ...ster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part...

Page 33: ...f such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 33 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 A Pillar Removal NOTE On driver s side...

Page 34: ...party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 34 Reach Body Servi...

Page 35: ...ed to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 35 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 76...

Page 36: ...s Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 36 Reach Body Service Manual E m...

Page 37: ...lity and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete...

Page 38: ...ssly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide informa...

Page 39: ...ustomers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 39 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Man...

Page 40: ...hoto copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 40 Reach Body Service Manual E mail custsvc utilimaster com Tray Panel Removal 1 Remove four M6 screws from tray panel 2 Remove panel and set a...

Page 41: ...essly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide inform...

Page 42: ...dental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated t...

Page 43: ...rial Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attem...

Page 44: ...omers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 44 Reach Body Service Manual E mail cu...

Page 45: ...ormation that is accurate complete and 45 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Doors Cab Slider NOTE The cab door handle and locking options vary Some of the most common types are described here To open the locked door from outside the cab insert the key and turn clockwise 1 4 turn until lock pops out then turn key ba...

Page 46: ...performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit ...

Page 47: ... expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide i...

Page 48: ...consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another ...

Page 49: ...nance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 49 For Assistance Call 800 237 7806 Parts On line https p...

Page 50: ...the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Cal...

Page 51: ...ance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 51 For Assistance Call 800 237 7806 Parts On l...

Page 52: ...hing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utili...

Page 53: ...r a particular purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evalu...

Page 54: ... consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another...

Page 55: ...ance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 55 For Assistance Call 800 237 7806 Parts On line https pa...

Page 56: ...ing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilim...

Page 57: ...ormance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Ut...

Page 58: ...support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 58...

Page 59: ...party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 59 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach ...

Page 60: ...ch products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 60 Reach Body Service Manual E mail custsvc utilimaster com Installation 1 Align exterior handle w...

Page 61: ...hird party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 61 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com R...

Page 62: ...isclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information t...

Page 63: ...d liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 63...

Page 64: ... performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimast...

Page 65: ...ehicles you are servicing Because Utilimaster manufactures customized vehicle bodies this document cannot list and illustrate every possible option for every vehicle The most common body options are described here Use this information as a guideline Refer also to the door manufacturer s service guide NOTE Safety application and operation instructions provided by the door manufacturer should always...

Page 66: ...y disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide informatio...

Page 67: ...vide information that is accurate complete and 67 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Removal 1 Close door 2 Remove cables See Remove Cables 3 Remove the hex head bolt and nut from stops located at the end of the track and remove stops 4 Slowly move door up and remove from top of track Installation 1 Lift and slowly ...

Page 68: ...y be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 68 Reach Body Service Manual E mail custsvc utilimaster com 5 Release the cable drum from the shaft by loosening the two set screws on th...

Page 69: ...he prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 69 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Panels Removal NOTE Before removing the bottom panel the cable needs to be removed See Remove Cables NOTE Remove hardware from panels to be used on repla...

Page 70: ...e and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster ...

Page 71: ... provide information that is accurate complete and 71 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Spring Adjustment NOTE A properly counterbalanced door should remain in the same position when stopped If the door leaves the floor by itself the spring is wound too tightly and a few quarter turns should be released If the door...

Page 72: ...d liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and Fo...

Page 73: ... all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is a...

Page 74: ...hose for vehicles you are servicing Because Utilimaster manufactures customized vehicle bodies this document cannot list and illustrate every possible option for every vehicle The most common body options are described here Use this information as a guideline Refer also to the door manufacturer s service guide NOTE Safety application and operation instructions provided by the door manufacturer sho...

Page 75: ...y for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 75 For Assis...

Page 76: ...attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 76 Reach Body Service Manual E mail custsvc utilimaster com Removal 1 Close door 2 Remove cables See Remove Cables 3 Remove the nuts washers and bolts from stops located at the end of the track and set aside 4 Slowly move door up and remove from tracks Installation 1 Lift ...

Page 77: ... copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 77 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 5 Release the cable drum from the shaft by loosening the two set screws on the cable drum a...

Page 78: ...formance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us ...

Page 79: ...er expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide...

Page 80: ...d liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and Fo...

Page 81: ...aterial Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation at...

Page 82: ...ovide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 82 Reach Body Service Manual E mail custsvc utilimaster com Springs Adjustment NOTE A properly counterbalanced door should remain in the same position when stopped If the door leaves the floor by itself the spring is wound too tightly and a few quarter turns should be released If the do...

Page 83: ...and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and ...

Page 84: ...ll respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is acc...

Page 85: ...sclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information th...

Page 86: ...d liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and Fo...

Page 87: ...ion use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 87 For Assistance Call 800 237 ...

Page 88: ...able for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document ma...

Page 89: ... the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written conse...

Page 90: ... reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 90 Reach Body Service Manual E mail custsvc utilimaster com Fuel Sending Unit Access Panel Composite Floor Located in the cargo area is an access panel fo...

Page 91: ...rior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 91 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Installation 1 Use a grinder to clean off any old structural adhesive 2 Clean contact surfaces at floor and on panel with isopropyl alcohol and allow to dry ...

Page 92: ... translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 92 Reach Body Service Manual E mail custsvc utilimaster com Glass Tools and Materials The following information can be shared with auto glass shops If you do the job yo...

Page 93: ...tion of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 93 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Windshield Tool Kit P N 23003394...

Page 94: ...ability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For As...

Page 95: ...age without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 95 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Quarter Glass Removal 1 Remove mirror See Remove Mirrors 2 Remove A pillar trim See Remove A Pillar Trim 3 Remove front quarter fender See R...

Page 96: ...s No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 96 Reach Body Service Manual E mail custsvc utilimaster com Glass Prep and Bonding 1 For windshield replacem...

Page 97: ... with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written ...

Page 98: ...dent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 98 Reach Body Service Manual E mail custsvc utilimaster com Windshield Instal...

Page 99: ...arty products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 99 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach B...

Page 100: ...amages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language withou...

Page 101: ...s in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the...

Page 102: ...rmance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at...

Page 103: ...ependent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 103 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Handrail Removal...

Page 104: ...consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another ...

Page 105: ...on use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 105 For Assistance Call 800 237 ...

Page 106: ...ined herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied rep...

Page 107: ...s contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo cop...

Page 108: ...rein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced...

Page 109: ...limaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No ...

Page 110: ...consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another ...

Page 111: ...lar purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of su...

Page 112: ...le for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may ...

Page 113: ...Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products ...

Page 114: ...ein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced ...

Page 115: ...se Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such produc...

Page 116: ...ed reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 116 Reach Body Service Manual E mail custsvc utilimaster com Condenser The condenser is located on the passenger side of the vehicle behind the bumper f...

Page 117: ...of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corpo...

Page 118: ...advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 118 Reach Body Service Manual E mail custsvc uti...

Page 119: ... may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 119 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 6 Remove trinary switch See Remove Trinary Switch 7 Remove two screws from dr...

Page 120: ...damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language witho...

Page 121: ...nd liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 1...

Page 122: ...le for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may ...

Page 123: ...ar purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of suc...

Page 124: ...shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of t...

Page 125: ...performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaste...

Page 126: ... or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or ...

Page 127: ...t be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this docu...

Page 128: ...master shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No pa...

Page 129: ...pose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such prod...

Page 130: ...formance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us ...

Page 131: ...be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this docume...

Page 132: ...a particular purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluat...

Page 133: ...ose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such produ...

Page 134: ...mages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without...

Page 135: ... material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation ...

Page 136: ...h the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written cons...

Page 137: ...d fitness for a particular purpose Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their indep...

Page 138: ... liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For...

Page 139: ...his material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporati...

Page 140: ...Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts t...

Page 141: ...ter shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part ...

Page 142: ...for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or tran...

Page 143: ...laims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that...

Page 144: ...ce or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilima...

Page 145: ...sly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide informat...

Page 146: ...ims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that i...

Page 147: ...ter expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provid...

Page 148: ...this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporat...

Page 149: ...se of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Co...

Page 150: ...terial Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation att...

Page 151: ...lete and 151 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Lights Grommet mounted Grommet mounted lights are used in a variety of areas including back up lights rear turn lights cab and cargo dome lights and brake lights Bullet lights mini marker lights and 4 round lights are all grommet mounted lights Removal NOTE To remove t...

Page 152: ... for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistanc...

Page 153: ...and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 153 For Assistance Call 800 237 7806 Parts On line https parts ...

Page 154: ...ility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complet...

Page 155: ...Utilimaster Corporation attempts to provide information that is accurate complete and 155 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Parking Light Removal 1 Turn off ignition and all lights 2 Turn the socket counterclockwise 3 Pull parking light out of socket and discard Installation 1 Turn off ignition and all lights 2 Sec...

Page 156: ...al damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language wi...

Page 157: ...r written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 157 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Mirrors Adjustment To receive maximum benefit from the outside mirrors adjust the driver s side mirror so you can see just a small amount of the side of the ve...

Page 158: ...ce maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www...

Page 159: ...tion of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 159 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Rear Vision System Camera Remov...

Page 160: ...aims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that ...

Page 161: ...le for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may ...

Page 162: ...iability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For A...

Page 163: ...ut the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 163 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Removal NOTE Refer to the instructions provided with the seat belt 1 Remove 7 16 20 nut and bolt from buckle and discard buckle 2 Remove cover from ...

Page 164: ...sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate comp...

Page 165: ...installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 165 For Assistance Cal...

Page 166: ...ly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide informati...

Page 167: ...lation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 167 For Assistance Call 800 ...

Page 168: ... for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistanc...

Page 169: ...on sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate c...

Page 170: ...ial Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attemp...

Page 171: ... accurate complete and 171 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Tools Fasteners and Adhesive Tapes Recommend Tools Below are some tools that may also be required in addition to the more commonly used hand tools drills wrenches etc vehicle body repair Drill bit set with drill stop NOTE Although not required the slightl...

Page 172: ...nsent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 172 Reach Body Service Manual E mail custsvc utilimaster com Fastener Replacement BOM Fastener Removal Use a die grinder to cut off the BOM fastener Use a center punch to knock out the center pin The remaining ring may need to b...

Page 173: ...lon insert nuts and KEPS nuts are reusable If locknuts are not available use lock washers and a thread adhesive like Loctite Flange head nuts and bolts can be used in place of flat washers Always use flat washers against aluminum surfaces Slowly torque the new bolt to the appropriate value Using a power tool to spin the fastener quickly may lower its effectiveness Nut Nutsert NOTE A nutsert is a t...

Page 174: ...translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 174 Reach Body Service Manual E mail custsvc utilimaster com Pine Tree Fastener Removal 1 Use a center punch or an air hammer with a punch attachment to place a hole in ...

Page 175: ...aster com Reach Body Service Manual Fax 574 862 7637 Tape Double Faced Adhesive Removal Use a razor knife to cut along the length of the tape while pulling apart the joined flat surfaces Scrape off remnants as much as possible Clean with a solvent Installation Apply to one surface from a fresh roll Do NOT remove the tape paper until the other surface is properly positioned Once the tape sticks to ...

Page 176: ...Sealant After removing the relevant fasteners use a razor knife to cut the sealant If necessary continue cutting while gently prying apart the sections Clean the reusable surfaces with isopropyl alcohol before applying new sealant Applying Sealant The following statements provide an overview of using polyurethane sealants Manufacturer s Recommendations Always follow manufacturer s cautions and rec...

Page 177: ...referred method for moving the vehicle Towing From the Front If a lowboy trailer is not available the recommended method of towing is with a front axle lift The drive shaft should be removed from the rear axle and left attached to the transmission to prevent fluid loss from the transmission Secure the drive shaft under unit The rear axle shaft may need to be removed if there is damage or suspicion...

Page 178: ...lete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 178 Reach Body Service Manual E mail custsvc utilimaster com Towing From the Rear Towing from the rear should be avoided if at all possible Weight transfer from lifting the rear axle can cause steering instability with the towing vehicle Lifting of the rear can also create a situation of exceeding the front Gross Axle Weight...

Page 179: ...quipment as appropriate to the process Become familiar with all warning labels Always maintain firm footing and control of tools Use safety stands and or wheel blocks whenever you are underneath the vehicle Be sure that the ignition switch is Off unless otherwise required by the procedure Put the transmission in Park and set the parking brake before working on the vehicle Operate the engine only i...

Page 180: ...d cleaner always use in a well ventilated area and follow directions on the can Wash and wax the body periodically to preserve the body finish Wipe interior surfaces with a clean damp cloth using only a mild soap and water Clean debris from screen covering the heater air intake Body Exterior Wash and wax the body periodically to preserve the body finish but avoid harsh cleaning solutions or high p...

Page 181: ...nificantly more impact resistant than laminated or tempered safety glass However because it is also less scratch resistant than glass take care when cleaning this type of window Use a mild soap or detergent and a clean sponge or soft cloth to wash the LEXAN window Rinse well with clean water To prevent water spots dry with a chamois or moist cellulose sponge Remove fresh paint splashes grease and ...

Page 182: ...ster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 182 Reach Body Service Manual E mail custsvc utilimaster com Lubrication Lubricate hinges latches seals and locks as described in the body maintenance checklist See Body Maintenance Checklist Manufacturers Recommendations Safety application and operation i...

Page 183: ...e of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Cor...

Page 184: ...nance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimas...

Page 185: ...e maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 185 For Assistance Call 800 237 7806 Parts On lin...

Page 186: ...s are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 186 Reach Body Service Manual E mail custs...

Page 187: ...ability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 187 Fo...

Page 188: ...er Parts Department Date 65528 State Road 19 P O Box 585 Wakarusa IN 46573 0585 U S A Preferred Shipper Fax 574 862 7637 Carrier and Service Priority Purchase Order Credit Card Authorized Signature Exp Date Vehicle Year Utilimaster Body S N or Chassis VIN Vehicle Model Order Item No Quantity Part Number Part Description Comments Optional 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Utilimaster Customer Ser...

Page 189: ...ration attempts to provide information that is accurate complete and 189 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Reporting Safety Defects United States Only If you believe that your vehicle has a defect that could cause a crash injury or death you should immediately inform the National Highway Traffic Safety Administrati...

Page 190: ...d liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and Fo...

Page 191: ...quential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to another langu...

Page 192: ...nguage without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 192 Reach Body Service Manual E mail custsvc utilimaster com C Cable hood 149 Cable rear roll up door 67 76 Camera rear vision 159 Catch 49 Bulkhead door 44 Slider door 49 51 55 Cladding 26 Fro...

Page 193: ...another language without the prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 193 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 Doors 41 Ajar switch 41 Bulkhead 42 Adjustment 42 Catch 44 Installation 43 Removal 43 Seals 44 Cab slider Catch front 49 Catch...

Page 194: ...ration attempts to provide information that is accurate complete and For Assistance Call 800 237 7806 Visit us at www utilimaster com 194 Reach Body Service Manual E mail custsvc utilimaster com Heater 10 104 Blower motor 105 Control module 117 Hoses 137 Mode motor 138 Resistor 140 Servo motor 138 Shut off valve 134 Thermostat 142 Hood 143 185 Adjustment 143 Assembly 146 Cable 149 Disassembly 145 ...

Page 195: ...e prior written consent of Utilimaster Utilimaster Corporation attempts to provide information that is accurate complete and 195 For Assistance Call 800 237 7806 Parts On line https parts utilimaster com Reach Body Service Manual Fax 574 862 7637 P Paint 180 Parking light 155 Parts Customizable order form 186 Ordering 186 Returning 187 Phone numbers 191 NHTSA 189 Transport Canada 189 Utilimaster P...

Page 196: ...l or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be photo copied reproduced or translated to ano...

Page 197: ...l Revision A December 2011 Part Number 03103361 VY12EN Important Notices 2011 Utilimaster Printed in U S A Title Reach Body Service Manual Utilimaster Corporation attempts to provide information that is accurate complete and useful All information contained in this manual is based on the latest product information available at the time of publication However because of the Utilimaster policy of co...

Page 198: ...for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Utilimaster expressly disclaims all respon sibility and liability for the installation use performance maintenance and support of third party products Customers are advised to make their independent evaluation of such products No part of this document may be ...

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