Cushman Shuttle 4 - Body; Section Title

TABLE OF CONTENTS FOR SECTION ‘C’
SECTION TITLE PAGE NO.
Page C-i
Repair and Service Manual
BODY
BODY ............................................................................................................................ C - 1
General ................................................................................................................................. C - 1
BODY COMPONENT REPLACEMENT ....................................................................... C - 1
Instrument Panel Replacement ............................................................................................ C - 5
Cowl Replacement................................................................................................................ C - 5
Front Fascia Replacement.................................................................................................... C - 5
Rocker Panel Replacement ................................................................................................. C - 5
Front Seat Pod Replacement ............................................................................................... C - 6
Rear Body Replacement....................................................................................................... C - 6
Foot Rest Replacement ........................................................................................................ C - 7
Rear Bumper Replacement .................................................................................................. C - 7
Front Seat Replacement....................................................................................................... C - 7
Front Facing Rear Seat ........................................................................................................ C - 8
Rear Facing Rear Seat ......................................................................................................... C - 8
Cargo Bed Replacement ...................................................................................................... C - 8
Seat/Cargo Bed Latch .......................................................................................................... C - 9
SHUTTLE 2 REAR BODY ............................................................................................ C - 9
Seat Support Removal........................................................................................................ C - 10
Rear Fender Removal ........................................................................................................ C - 10
Rear Valence Panel Removal............................................................................................. C - 11
Side Panel Removal ........................................................................................................... C - 11
Load Deck Removal ........................................................................................................... C - 11
Bulkhead Removal.............................................................................................................. C - 12
Seat Back Removal ............................................................................................................ C - 12
Bed Frame Removal........................................................................................................... C - 13
Seat Frame Removal .......................................................................................................... C - 13
Mid Support Removal ......................................................................................................... C - 14
Rear Bed Bracket Removal ................................................................................................ C - 14
PAINTING ................................................................................................................... C - 15
Minor Scratches.................................................................................................................. C - 15
Large Scratches.................................................................................................................. C - 15
Complete Panel Repair....................................................................................................... C - 15
LIST OF ILLUSTRATIONS
Fig. 1 Drill Out Metal Rivet............................................................................................................... C - 1
Fig. 2 Body Components (Front) ..................................................................................................... C - 2
Fig. 3 Body Components (Seats and Rear)..................................................................................... C - 3
Fig. 4 Body Components (Cargo Box, Seat, Foot Rest).................................................................. C - 4
Fig. 5 Shuttle 2, Rear Body ............................................................................................................. C - 9
Fig. 6 Seat Support Removal ........................................................................................................ C - 10
Fig. 7 Rear Fender Removal ......................................................................................................... C - 10
Fig. 8 Rear Valence Panel Removal ............................................................................................. C - 11
Fig. 9 Side Panel Removal ............................................................................................................ C - 11
Fig. 10 Load Deck Removal .......................................................................................................... C - 12
Fig. 11 Bulkhead Removal ............................................................................................................ C - 12
Fig. 12 Seat Back Removal ........................................................................................................... C - 12
Fig. 13 Bed Frame Removal.......................................................................................................... C - 13
Fig. 14 Seat Frame Removal......................................................................................................... C - 13
Fig. 15 Mid Support Removal ........................................................................................................ C - 14
Fig. 16 Rear Bed Bracket Removal ............................................................................................... C - 14