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Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com
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USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
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FOR DISTRIBUTION
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Body Panel Replacement:
1. When replacing exterior body panels, remove rivets following procedures outlined below.
2. Apply sealant to new panel as required.
3. Install new panel in reverse order.
Removing A Rivet:
1.
When removing an existing rivet, place the drill bit on the small dot in the center of the
rivet head. Twist the drill chuck by hand to enlarge the small dot. This will prevent the drill
from slipping.
2. *Never drill completely through the rivet or you risk enlarging the hole which can weaken
the bond when re-fastened. Drill into the center of the rivet head. With drill turned off
but still in place, move it horizontally and vertically until the head of the rivet comes off.
Use an awl and a mallet to tap the rivet shank out.
3.
If you accidentally drill through the material, see the following instructions.
Re-Riveting:
1. When replacing new panels, use .19 diameter rivets. The correct length rivet will measure
.25-.38 beyond the material being joined. (See diagram below)
2. When ever rivets are removed there is always some enlargement to the hole. To ensure
the strength of the new bond, follow these steps.
3. Drill the hole out to .25” diameter. If the hole is already .25” diameter then drill it out to
.28” diameter and use a .25” bolt and nut, otherwise continue to the next step.
4. Rivet the parts using a .25” rivet. The correct length rivet will measure .25-.38 beyond the
material being joined.
NOTE: As the vehicle ages, it is not uncommon for some rivets to loosen. This can often
be detected by a black ring (aluminum oxide) around the head of the rivet. If this happens
replace the rivet. See Re-Riveting.
BODY PANEL REPLACEMENTS & RIVETS
Windshield Removal:
1. Special tools are required for windshield removal. Glass and Bead Tools.
2.
A soap and water solution should be applied around the rubber seal. This will allow the
tools to move smoothly when in contact with the rubber seal.
3. Using the glass tool pry between the windshield and the rubber seal. This will enable
you to pry the glass from the seal. Leaving the tool in position work your way around the
glass. Pushing the top corners of the windshield from inside the truck will get the removal
process started.
NOTE: For safety reasons this task should be performed by two people.
Windshield Installation:
1. Special tools are required for windshield removal. Glass and Bead Tools.
2. Insert rubber seal into window frame.
3.
A soap and water solution should be applied around the rubber seal. This will allow the
tools to move smoothly when in contact with the rubber seal.
4.
Position the bottom of the windshield in place first. Using the glass tool pry the lip on the
seal out to allow the windshield to seat in the seal properly. Work your way around the
window until it is seated properly.
5.
Do this around the whole windshield until the windshield seats properly in the frame.
WINDSHIELD REPLACEMENT
