2001 Canada Post Body Service Manual

Transcript

Body Service Manual Canada Post Read First: Top Tips on Using This Online Manual Browse pages with Bookmarks (hyperlinks) or Thumbnails Bookmarks, at the left of the screen, are hyperlinks to document pages. From any page in this document, you can use bookmarks to jump to any section heading. To jump to a topic by using its bookmark, point to the bookmark name, and when the arrow becomes a pointing hand, click on the name. If a triangle (or + sign) appears to the left of the bookmark, click the triangle (or + sign) to show or hide subordinate bookmarks. Thumbnails are visual icons of the actual pages. After selecting the thumbnail view button (Acrobat Reader ver. 3.0) or tab (ver. 4.0), you can quickly browse for parts sections just by the “look” of the page. Click on the appropriate thumbnail to view that page. Use the Zoom and Fit tools for magnification of page sections Select the Zoom tool. (In ver. 4.0, when the Hand tool is selected, you can temporarily change to the Zoom tool by holding down the Ctrl key and the space bar at the same time.) Click and drag to draw a rectangle around the area you want to magnify. To return to an overview, you can click on one of the following buttons: • • The Fit Page button scales the entire page to display within the main window. The Fit Width button scales the page width to display within the main window. Use the Text tool for copying selected text into other applications You can select text in a PDF document, copy it to the Clipboard, and paste it into another application. By pasting parts descriptions and numbers into your email, you can order parts much faster than through phoning or faxing. To select text and copy it to the Clipboard: 1. Click the Text Selection tool. 2. Click and drag over the text you want to select. When you release the mouse button, the selected text stays highlighted. 3. Hold down the Ctrl key and press C on the keyboard to copy the selected text to the Clipboard. Find parts or procedures with the Find tool Use the Find tool to search for a fragment of a word, a complete word, or multiple words in the active document. To find a word (e.g., a part name): 1. Click the Find tool. 2. In the Find What text box, enter the text to be found and click Find. When the program finds the text, the Find dialog box closes and the page containing the text is displayed with the text highlighted. 3. To find the next occurrence of the word, press F3, press Ctrl + G, or reopen the Find dialog box and click Find Again. 2 Canada Post Body Service Manual Part Number: 03102466-VY01EN Revision Control Revision Print Date Release A October 2001 The latest updates and other information about parts and service will be available for viewing and downloading at www.utilimaster.com/candpost. Check that page for the latest information. Important Notices ©2001, Utilimaster. Printed in U.S.A. ® Title: Canada Post Body Service Manual NOTE: When phoning Utilimaster, be aware that our 219 telephone area code is changing to 574 in January 2002. The 800 numbers will be unaffected. 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 continual product improvement, Utilimaster reserves the right to amend the information in this document at any time without prior notice. Should you find inadequacies in the text, please send your comments to the following address: Utilimaster Corporation Attn: Designer of Technical Publications 65906 State Road 19, P.O. Box 585 Wakarusa, IN 46573–0585, U.S.A. This material is confidential and the property of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equipment. 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 responsibility 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 photocopied, reproduced, or translated to another language without the prior written consent of Utilimaster. Utilimaster® is a registered trademark of Utilimaster Corporation. All other products or name brands mentioned in this document are trademarks of their respective owners. Browse www.utilimaster.com for more information about Utilimaster and its products. For manual updates and other important information, visit www.utilimaster.com/candpost, the Canada Post page on our award-winning web site. Canada Post Body Service Manual 3 Contents Revision Control ......................................................................................................................... 3 Important Notices ....................................................................................................................... 3 Introduction ................................................................................................................................ 7 Overview .................................................................................................................................... 8 VIN and Utilimaster Body Serial Number ................................................................................... 9 Ordering Parts .......................................................................................................................... 10 Warranty ................................................................................................................................... 11 Safety Considerations .............................................................................................................. 13 Towing ...................................................................................................................................... 13 Emergency Repairs .................................................................................................................. 13 Service Information .................................................................................................................. 14 1.0 Body Maintenance Checklist......................................................................................... 14 1.1 Pre-Trip Inspection (daily) ................................................................................................................... 14 1.2 Routine Body Maintenance (every three to four months) .................................................................... 14 2.0 Tools and Fasteners ..................................................................................................... 18 2.1 Common Tools .................................................................................................................................... 18 2.2 Removal and Replacement of Fasteners ............................................................................................ 19 2.3 Lengths of Buck Rivets ....................................................................................................................... 23 2.4 Torque Values ..................................................................................................................................... 25 2.5 Body Sealants ..................................................................................................................................... 27 3.0 Windows ....................................................................................................................... 28 3.1 Windshield and Quarter-Windows ....................................................................................................... 28 3.2 Side Door with Sliding Window ........................................................................................................... 34 3.3 Side Door with Roll-up Window ........................................................................................................... 37 4.0 Wiper/Washer System .................................................................................................. 40 4.1 Wiper System Troubleshooting Procedure .......................................................................................... 41 4.2 Wiper Motor ........................................................................................................................................ 44 4.3 Pivot and Link Assembly ..................................................................................................................... 45 4.4 Wiper Blade Assembly ........................................................................................................................ 46 4.5 Wiper Arms ......................................................................................................................................... 47 4.6 Pivot Assembly ................................................................................................................................... 48 4.7 Washer Bottle ..................................................................................................................................... 50 4 Canada Post Body Service Manual 5.0 Doors ............................................................................................................................ 51 5.1 Keys ................................................................................................................................................... 51 5.2 Rear Roll-Up Door .............................................................................................................................. 52 5.3 Side Sliding Doors .............................................................................................................................. 62 5.4 Bulkhead Door .................................................................................................................................... 70 6.0 Hood ............................................................................................................................. 71 6.1 RIM Hood Surface Repair ................................................................................................................... 71 6.2 Gas Springs ........................................................................................................................................ 72 6.3 Hood Removal and Replacement ....................................................................................................... 72 6.4 Hood Adjustment ................................................................................................................................ 74 6.5 Fenders .............................................................................................................................................. 76 6.6 Grill ..................................................................................................................................................... 77 7.0 Seats and Seat Belts .................................................................................................... 78 7.1 Driver’s Pedestal ................................................................................................................................. 78 7.2 Driver’s Seat ....................................................................................................................................... 78 7.3 Seat Belt Maintenance ........................................................................................................................ 80 7.4 Driver’s Seat Belt ................................................................................................................................ 82 7.5 Jump Seat .......................................................................................................................................... 83 7.6 Jump Seat Belts .................................................................................................................................. 85 8.0 Heating System............................................................................................................. 87 8.1 Blower Motor ....................................................................................................................................... 88 8.2 Heater Resistor ................................................................................................................................... 88 9.0 Lights and Wiring ..........................................................................................................89 9.1 Wiring ................................................................................................................................................. 89 9.2 Headlight Replacement and Adjustment ............................................................................................. 89 9.3 Forward Turn Signal Light ................................................................................................................... 91 9.4 Front Side Marker Light ...................................................................................................................... 91 9.5 Clearance and Identifcation Lights ...................................................................................................... 92 9.6 Taillights (Brake, Back-Up, Hazard, and Turn) .................................................................................... 92 9.7 License Plate Light.............................................................................................................................. 93 9.8 Dome (Cab) Light ............................................................................................................................... 93 9.9 Cargo Lights ....................................................................................................................................... 93 9.10 Dash Switch (Cargo, Dome) ............................................................................................................. 94 Canada Post Body Service Manual 5 10.0 Miscellaneous Repairs ................................................................................................ 95 10.1 Grab Handle ..................................................................................................................................... 95 10.2 Roof Vent .......................................................................................................................................... 96 10.3 Sun Visor .......................................................................................................................................... 97 10.4 Mirrors .............................................................................................................................................. 98 10.5 Rear Kazoo (Duck–Bill) Drain Valves ................................................................................................ 99 10.6 Dash Panel Assembly (Ford) .......................................................................................................... 100 11.0 Body Repairs ............................................................................................................. 103 11.1 Roof Assembly ................................................................................................................................ 104 11.2 A-post .............................................................................................................................................. 108 11.3 Center Post ..................................................................................................................................... 108 11.4 Quarter Panel .................................................................................................................................. 109 11.5 Paint ................................................................................................................................................. 110 11.6 Decals .............................................................................................................................................. 113 11.7 Rear Bumper .................................................................................................................................... 114 Index ...................................................................................................................................... 115 6 Canada Post Body Service Manual Introduction This manual includes service and maintenance procedures for the Canada Post walk-in van body manufactured by Utilimaster® Corporation. It contains drawings to aid in servicing the vehicle, and it may include maintenance information on some items installed but not manufactured by Utilimaster. Items such as chassis and drive train components or certain interior furnishings are covered by separate manufacturer-supplied information. All information, specifications, and illustrations contained in this manual are based on the latest product information available at the time of publication. Utilimaster reserves the right to amend the information in this document at any time without prior notice. This vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy if metric tools must be used, but Utilimaster does not warrant metric values given in this manual. See the following manuals for additional information: · Canada Post Body Operator’s Guide (P/N 03102466–RY01EN [English version] or P/N 03102466–RY01FR [French version]) for information about vehicle operation. · Canada Post Body Wiring Manual (P/N 03102466-WY01EN [English version] or P/N 03102466-WY01FR [French version]) for information about electrical wiring schematics. · Canada Post Body Parts Manual (P/N 03102466–PY01EN) for information about replacement parts. Canada Post Body Service Manual 7 Overview Identification Lights Clearance Lights Rear Door Identification Lights Clearance Lights Heated Mirrors Hood Turn/Hazard Light Grab Handle Stop/Tail Light Headlight Back-up Light Turn Signal Hood Strap Rear Bumper Reflector Block Heater Plug Bumper Step Safety Cable Latch License Plate Lights Pull Strap Side Marker Light ADVERTISEMENT FRAME Heated Mirror 1-800-267-1 www .postescanada.ca 177 www .canadapost.ca Side Marker Light Reflector Fuel Fill Port Reflector Lower Rub Rail Rub Rail 8 Canada Post Body Service Manual VIN and Utilimaster Body Serial Number You will need the VIN or Utilimaster Body Serial Number to order parts and make warranty claims. The chassis Vehicle Identification Number (VIN) is the legal identifier for this vehicle. It is the number recorded in the license plate registration. The VIN appears on a small metal plate on the dash, facing the window. You can read the VIN if you look through the quarter panel window. The number is also recorded on the Certification Label (see below). The Utilimaster Unit (or Body) Serial Number is recorded on the Certification Label. This label is a plastic decal (about 28 cm long and 5 cm high) that contains manufacturing information (including the VIN). This label is near the top of the door frame between the driver’s window and the quarter-panel window. Vehicle Identification Number Certification Label Canada Post Body Service Manual 9 Ordering Parts To order parts for this vehicle, gather the following information: • Model and year of vehicle (200_ Canada Post). • Chassis VIN, Utilimaster Body Number, or Asset Number (see below). • Complete shipping address. • Preferred method of shipping. • Complete description of all the parts necessary (see the Canada Post Body Parts Manual, P/N 03102466–PY01EN). • Method of payment. NOTE: Customer Service prefers payment by Visa, MasterCard, Discover, or American Express credit cards. Purchase Orders from customers with established open accounts are also accepted. Then contact Utilimaster Customer Service by using one of the following methods: • Email your order to [email protected]. (From www.utilimaster.com you can download the customizable Utilimaster Parts Order Form Template that can be emailed, mailed, or faxed.) • Fax your order to 219–862–7637. • Call 800–237–7806 (219–862–3219) and ask for the Parts Department. • Mail or express service your order to the following address: Utilimaster Corp. Attn: Parts Department NOTE: When phoning Utilimaster, be aware that our 65528 State Road 19 219 telephone area code is changing to 574 in P.O. Box 585 January 2002. The 800 numbers will be unaffected. Wakarusa, IN 46573-0585 U.S.A. To return parts for credit, call the Customer Service Department for prior authorization. All returns must be shipped prepaid freight. A restocking fee will be charged to all returns. Special-order parts are not returnable. 10 Canada Post Body Service Manual Warranty The warranty is issued to the original purchaser and is neither transferable to nor enforceable by any other person. Utilimaster Corporation warrants that the body shall be free from defects in factory materials and workmanship made or supplied by Utilimaster under normal use and service, in accordance with and for the specified period. The warranty begins on the in-service date. The chassis, engine, tires, battery, and drive train are warranted separately by the manufacturers of those components. Filing Warranty Claims If a problem on the Utilimaster body is caused by a defect in materials or workmanship, it will be covered by our Limited Warranty. Claims must meet the requirements listed below. Failure to meet these requirements may result in a denied or delayed claim. Complete a repair order with the following information: · Owner’s and/or service facility’s name. · Service center representative’s signature. · Chassis VIN, Utilimaster Body/Unit Serial Number, or Asset Number. · Date vehicle was repaired. · Mileage at time of failure. · Itemized description of the problem. Complaint Cause of failure (if known) Correction (describe in detail) · Service center labor rate and total time of repair. · Total claim amount, including cost of parts, labor, miscellaneous charges, and sales tax (if applicable). · Your claim or repair order number. NOTE: Your claim or repair order number is the number used to match Utilimaster payment with the work done. It will be noted on your payment. · Utilimaster authorization number (for repairs costing over $500 U.S.). The claim can be mailed, faxed, emailed, or performed on-line on our web site (assuming all required information is included). NOTE: When phoning Utilimaster, be aware that our · Warranty claims should be mailed to: 219 telephone area code is changing to 574 in Utilimaster January 2002. The 800 numbers will be unaffected. Attn: Warranty Department 65528 State Road 19 P.O. Box 585 Wakarusa, IN 46573–0585 U.S.A. Canada Post Body Service Manual 11 · Alternately, you can fax your claim (if no photographs are involved) with the above information to 219–862–7637. (The resolution of the received copies must be acceptable, or you will be asked to mail your hard copies.) · Or you can email your claim with the above information to [email protected]. · You can also download a customizable Warranty Claim Form template from the Utilimaster web site www.utilimaster.com. Other claim requirements: · Any repairs over $500 U.S. or for structural warranty require prior authorization from Utilimaster, and that number must appear on the repair order. · Any claim that is not legible and complete will be returned for completion. · All paint claims require pictures, estimates, and prior authorization. · Shipping damage claims also require pictures, estimates, and prior authorization. The damage must also be noted on the Delivery Acceptance form. This form requires the signature of the carrier driver. · Sublet work must have the sublet repair order attached to the service facility’s repair order that is being submitted. · Claims must be submitted within 30 days after the repair is completed. If the return of a failed part is requested, contact a Utilimaster warranty representative for a return goods authorization (RGA). Please reference that number with the returned part and enclose a copy of the repair order. Shipping charges should be entered on the same repair order that is submitted for warranty payment. COD charges for a returned parts will not be accepted, and the part will be returned. Chassis, engine, tires, and battery failures are covered by the individual manufacturers. Claims are paid semimonthly. Utilimaster generally does not pay sales tax on claims. If you do not have our tax exemption number on file, please call 800–528–3454 or 219–862–4561 and ask for the accounting department to obtain the number. NOTE: When phoning Utilimaster, be aware that our 219 telephone area code is changing to 574 in January 2002. The 800 numbers will be unaffected. 12 Canada Post Body Service Manual Safety Considerations As you read this guide, you will come across NOTES, CAUTIONS, and WARNINGS. NOTES give you additional information that will help you to complete the procedure. CAUTIONS warn you against making an error that could damage the vehicle. WARNINGS remind you to be careful where there is a risk of personal injury. The following list contains some WARNINGS that you should follow when you work on the vehicle. · Always wear safety glasses. · Be familair with all warning labels. · 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 in a well-ventilated area to avoid carbon monoxide poisoning. · Avoid contact with hot metal parts such as the radiator or exhaust system. · Do not smoke while working on the vehicle. · Always remove rings, watches, hanging jewelry, and loose clothing before working on a vehicle. Tie long hair securely behind your head. · Keep hands and other objects clear of the radiator fan blades and any moving parts when the engine is running. Disconnect the fan when working under the hood. An increase in temperature under the hood can cause the fan to start at any time even though the ignition is OFF. Towing See the Ford Operator’s Guide for complete details. If the vehicle needs towing, a wheel lift or flatbed equipment is recommended. Utilimaster recommends the vehicle be unloaded to reduce stress on the chassis during towing. If towing, be sure to release the parking brake and place the transmission in neutral. Emergency Repairs Problems with the Utilimaster body are unlikely to disable a vehicle enough to make it undrivable. See the Ford Operator’s Guide and the engine service manual for more details. Canada Post Body Service Manual 13 CAUTION: Do not power wash for the first 90 days. Wash and wax the body periodically to preserve the body finish, but avoid harsh cleaning solutions or high-pressure washes. CAUTION: Only use engine coolant(s) recommended by the chassis manufacturer. All deviations from the recommended coolant and all cooling system additives must be approved by the chassis manufacturer and Utilimaster Corporation. Service Information 1.0 Body Maintenance Checklist By design, the Utilimaster body is low maintenance. Most of the body is sturdy, lightweight, rust-free aluminum. However, Utilimaster recommends the following items should be checked every three to four months, unless otherwise stated. For more detailed information, check the relevant sections of the manual. 1.1 Pre-Trip Inspection (daily) The driver should perform the following checks each day: q q q q q q q q q q q Adjust the driver’s seat position. Adjust all mirrors. Fasten and adjust the safety belt. When starting the engine, check all warning lights on the instrument panel. Check all switches on the dash and the steering column to see that they work properly Check heater and defroster controls. Check wiper operation. Check washer operation and spray pattern. Check washer fluid level. Check all exterior and interior lights. Check the operation of all doors. 1.2 Routine Body Maintenance (every three to four months) Utilimaster recommends that a technician do the above pre-trip inspection before performing the following body maintenance checks: 1.2.1 Seats and Belts q Check tightness of seat belt and pedestal bolts. q Check seat belt for operation and signs of fraying or wear. 14 Canada Post Body Service Manual 1.2.2 Interior Driver Conveniences q Check heating system for operation and ease of use. q Check all switches for operation. 1.2.3 Windshield Washer and Wipers q Check tightness of the wiper linkage connections. q Check that the blades wipe clean. 1.2.4 Hood q Check release latches for alignment and excessive wear. q Check hood guides for alignment and excessive wear. q Check hood struts for proper operation. 1.2.5 Bumpers Catch Plate q Check bolts on the bumper brackets for tightness. q Check for damaged or bent components. 1/8" (3.2 mm) 1.2.6 Doors Latch q Check the sliding window and window Tongue latch operation. q Check the crank-up window operation. Illustration 1–1 Check the Latch q Check that doors open easily and close Tongue and Catch Plate for Wear tightly. q Check interior and exterior handles for tightness. q Check alignment of latches and catches. (See Illustration 1–1.) q Check for wear on bulkhead and sliding door catch plates and latch tongue. At least 1/8" (3 mm) of the Kason latch tongue needs to engage the catch plate. q Check operation of locks. q Check condition of the pull-down strap on rear door. q Check that the rear door is centered in the opening. q Apply lock antifreeze in the winter. q Lubricate locks and latches with a lightweight oil. (Utilimaster recommends Exxon Hydraulic oil type NUTO #68, or equivalent, for the lock cylinders.) CAUTION: Do not use grease on the door. Do not get oil on rubber seals. Wipe up any drips immediately. Canada Post Body Service Manual 15 q Lubricate the rear roll-up door with a light oil Utilimaster P/N 04202540, or equivalent. (See Illustration 11–2.) • Roller shafts—wipe off excess oil (#1 and #3). • Springs—lube both springs along their entire length to prevent rusting (#2). • Track—clean and lube (#4). • Hinges (center and end)—wipe off excess oil (#5). • Rollers (#6 and #7). • Latches. • Lock cylinder—wipe off excess oil. NOTE: The information in this illustration is generic. Details may differ from your vehicle. Use this information as a guideline where it applies. CAUTION: Do not use grease on the door. Do not get oil on rubber seals. Wipe up any drips immediately. Counterbalance Shaft Track Spring Drum Roller Hinges Roller Shaft Roller Bracket Illustration 1–2 Places to be Lubricated on a Rear Roll-up Door 16 Canada Post Body Service Manual 1.2.7 Other Body Parts q Check for loose or missing fasteners underneath the chassis, particularly the body mounting bolts on the outside of the riser on either side of the chassis rails, the bolts on the crossmember plate, and the Huck rivets. (See Illustrations 1–3.) q Check that all reflective tape is securely attached. q Clean rear threshold drains and drain troughs. q Check grab handle mounting bolts for tightness. q Check mirror mounting bolts for tightness. Rail Riser Crossmember Plate Illustration 1–3 Check for Loose Bolts on the Chassis Canada Post Body Service Manual 17 2.0 Tools and Fasteners 2.1 Common Tools Below are tools, including recommended brands and models, commonly used in walk-in van repairs. Note that this vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy if metric tools must be used, but Utilimaster does not warrant metric values given in this manual. 18 • Phillips and flathead screw driver set including Torx® bit • Metric and standard box and open-end wrench set • 3/8" (10 mm) drill (Dewalt® DW221 recommended) • 1/2" (13 mm) drill (Dewalt® DW231 recommended) • Drill bit set • Screw gun (Dewalt® DW281 recommended) • Pop riveter (Emhart® PRG 540 recommended as it does both pop rivet and monobolt installation) • Monobolter (Emhart® PRG 540 with 1/4" nose assembly (consisting of Jaws PRG 540-44, Jaw Pusher PRG 740-7A, and 1/4" Nose Tip BRN-811) • Air hammer with a buck riveter attachment (Sioux 270 with 3/16" Ajax rivet set #1620) and bucking bar • Huck riveter (Huck 229 with 1/4" nose assembly 99-1458) • Saber saw (Porter Cable 548) • DVOM (Digital Voltmeter) • Terminal tool kit (Snap-On TT600 recommended) • Locking pliers (VISE-GRIP® recommended, about 9" or 10" [23 or 25 cm] long) • Multigrips or tongue and groove pliers (any standard model about 9" or 10" [23 or 25 cm] long) • Needle-nose pliers • Torque wrenches (any quality sets with in•lb and ft•lb [or N•m] measurements) • Drill stop • Hand punch or an air hammer punch attachment • Disk Air sander with 220, 320, and 600 grit sandpaper • Tape measure • Fine-pointed marker • Razor knife Canada Post Body Service Manual 2.2 Removal and Replacement of Fasteners 2.2.1 Buck (Small, Solid Brazier-Head) Rivet 2.2.1.1 Removal Use a #11 (3/16" [5 mm] if #11 is not available) drill bit to drill off the head of the rivet, starting at the dimple located in the center. Continue to drill the rivet until the head pops off. Take a punch and knock out the stems. NOTE: Brazier-head 3/16" (5 mm) buck rivets of varying lengths are used on most locations on the body. (See Section 2.3.) Illustration 2–1 Buck Rivet Use an air hammer with a buck riveter attachment and bucking bar to replace the rivet. (See Illustration 2–1.) 2.2.2 Pop Rivet 2.2.2.1 Removal Illustration 2–2 Pop Rivet Drill off the head of the rivet using a #11 (3/16" [5 mm] if #11 is not available) drill bit. The back stem should fall off. (See Illustration 2–2.) 2.2.2.2 Replacement Use a pop rivet gun to replace it. 2.2.3 Monobolt (Magna-Bulb® and Magna-Lok®) Illustration 2–3 Magna-Bulb® 2.2.3.1 Removal 1. With a punch (or an air hammer with a punch attachment), knock the stems out of the fasteners. (See Illustrations 2–3 and 2–4.) 2. Drill off the head of the rivet using a #11 (3/16" [5 mm] if #11 is not available) or F (1/4" [6 mm] if F is not available) drill bit, depending on size. The back stem should fall off. Illustration 2–4 Magna-Lok® 2.2.3.2 Replacement Use a monobolt rivet gun to replace it. Canada Post Body Service Manual 19 2.2.4 Pin and Collar Rivet (Magna-Grip®) 2.2.4.1 Removal From the head side, using the appropriate-size drill bit (1/4" [6 mm], 3/16" [5 mm], or 3/8" [10 mm]), drill off the head of the pin. Punch out the center of the remaining pin. (See Illustration 2–5 and 2–6.) From the collar side, using the appropriate-size drill bit (1/4" [6 mm], 3/16" [5 mm], or 3/8" [10 mm]), drill out the center of the collar. Punch out the center of the remaining pin. NOTE: Be extremely careful not to overheat the steel pin and collar. Use low-RPM drill speed. Illustration 2–5 Magna-Grip® with Collar Illustration 2–6 Magna-Grip® with Flanged Collar Or from the collar side, the rivet can be cut off with a die grinder or a reciprocating saw. Punch out the pin from the remaining ring. 2.2.4.2 Replacement Use a Huck rivet gun to replace it. If a Huck rivet gun is not available, replace the fastener with a Grade 8 bolt of like diameter and a Grade 8 locknut. For additional locking capacity, use Loc-Tite. NOTE: Flat washers are required against aluminum surfaces. 2.2.5 BOM® Fastener 2.2.5.1 Removal A BOM® fastener must be cut off with a die grinder. Punch out the center pin. The remaining ring may need to be punched out or drilled out. (See Illustration 2–7.) Illustration 2–7 BOM® Fastener 2.2.5.2 Replacement Replace with a Grade 8 bolt of like diameter and a Grade 8 locknut. For additional locking capacity, use Loc-Tite. NOTE: Flat washers are required against aluminum surfaces. 20 Canada Post Body Service Manual 2.2.6 Locknuts 2.2.6.1 Removal Locknuts can be removed with an appropriate open-end or box-end wrench. 2.2.6.2 Replacement Since used locknuts distort the threads, they should be discarded and replaced with new locknuts. The bolt should be discarded as well. CAUTION: Utilimaster uses center-lock type locknuts which distorts the threads of the nut and bolt. This type should not be reused after disassembly. Always replace with new. 2.2.7 Nutsert NOTE: A nutsert is a threaded insert that is crimped into place. A nutsert need only to be removed if it is damaged and cannot be retapped. 2.2.7.1 Removal Cut off with a die grinder. (See Illustration 2–8.) 2.2.7.2 Replacement Using a nutsert insert tool, replace the nutsert with one meeting original specifications. Illustration 2–8 Nutsert If a nutsert of original specifications or the tool to install nutserts is not available, the nutsert may be replaced with another form of threaded insert or a nut and bolt. This depends upon application and should be approved by Utilimaster Customer Service. If it is to be replaced with a nut and bolt, it is important to use flat washers on both sides of the material. CAUTION: Do not use Loc-Tite on the threads of a nutsert. 2.2.8 Vinyl Barrier Tape White vinyl tape is used wherever steel and aluminum surfaces mate in order to prevent corrosion of the surfaces. 2.2.8.1 Removal Peel or scrape off. 2.2.8.2 Replacement Apply to mating surfaces from a fresh roll. NOTE: Tape rolls can be ordered by the following part numbers: 1" (2.5 cm) – wide roll (P/N 12303707) 2" (5 cm) – wide roll (P/N 12303706) 3" (7.6 cm) – wide roll (P/N 12303705) 4" (10 cm) – wide roll (P/N 12605947) Canada Post Body Service Manual 21 2.2.9 Double-faced Adhesive Tape 2.2.9.1 Removal With a razor knife, 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. 2.2.9.2 Replacement Apply to clean surface from a fresh roll. Do not remove the tape paper until the other surface is in the proper position. Once the tape sticks to a surface, you will not be able to reposition it without starting over. 2.2.10 Bolts with Thread Adhesive 2.2.10.1 Removal Bolts with thread adhesive cannot be reused. After the bolt is removed and discarded, check the surface and scrape off any remaining adhesive residue from the seal before continuing with the repair or replacement. 2.2.10.2 Replacement Slowly torque the new bolt to the appropriate value. (Using a power tool to spin the fastener quickly may lower the effectiveness of the seal.) 2.2.11 Torque Seal Torque seal appears as a small painted line across a bolt thread and nut or across a bolt and washer seam. If the seal line is broken (out of alignment), the fastener has loosened. 2.2.11.1 Removal After the bolt is removed and discarded, check the surface and scrape off any remaining adhesive residue from the seal before continuing with the repair or replacement. 2.2.11.2 Replacement Torque to specification first, then apply a small bead of torque seal or paint stick across the new bolt threads, nut, head, and/or washer. NOTE: Paint stick can be used to mark that a bolt has been torqued to specification but it will not serve as an indicator that the fastener has backed off or loosened. NOTE: Torque seal or paint stick may be used in the following locations: 22 • Front and Rear Bumpers • Body Mounting Bolts (See Section 1.2.7.) • Seat Restraint System • Seat Pedestal Canada Post Body Service Manual 2.3 Lengths of Buck Rivets Rivet Diameter 3/16" (4.76 mm) This vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy if metric tools must be used, but Utilimaster does not warrant metric values given in this manual. Rivet Length Metal Rivet Grips 7/16" (11.1 mm) .244" (6.2 mm) 3/16" to 15/64" (4.8 to 6.0 mm) 1/2" (12.7 mm) .305" (7.7 mm) 1/4" to 19/64" (6.4 to 7.5 mm) 9/16" (14.3 mm) .364" (9.2 mm) 5/16" to 23/64" (7.9 to 9.1 mm) 5/8" (15.9 mm) .424" (10.8 mm) 3/8" to 27.64" (9.5 to 10.7 mm) 3.4" (19.1 mm) .545" (13.8 mm) 7/16" to 17/32" (11.1 to 13.5 mm) 7/8" (22.2 mm) .665" (16.9 mm) 35/64" to 21/32" (13.9 to 16.7 mm) Canada Post Body Service Manual Metal Thickness 23 Rivet diameter, in. 1/16 3/32 1/8 3/32 3/16 1/4 5/16 3/8 Hole diameter, in. 0.067 0.096 0.1285 0.159 0.191 0.257 0.323 0.386 51 41 30 21 11 F P W ..... ..... ...... ..... Drill no. Rivet length, in. 1/16 Maximum rivet grips for given lengths in inches* 0.110 0.091 0.061 0.033 1/4 0.164 0.151 0.120 0.094 0.064 ..... ..... ..... 3/16 0.218 0.210 0.180 0.153 0.124 0.062 ..... ..... 3/8 0.272 0.270 0.239 0.214 0.184 0.122 0.062 ..... 7/16 ..... 0.330 0.297 0.275 0.244 0.182 0.122 0.067 1/2 ..... 0.389 0.356 0.334 0.305 0.240 0.181 0.124 9/16 ..... 0.449 0.416 0.395 0.364 0.300 0.241 0.184 5/8 ..... ..... 0.475 0.456 0.424 0.360 0.299 0.244 3/4 ..... ..... 0.594 0.577 0.545 0.477 0.416 0.360 7/8 ..... ..... ..... 0.697 0.665 0.595 0.534 0.476 1 ..... ..... ..... ..... 0.785 0.715 0.650 0.596 1-1/4 ..... ..... ..... ..... ..... 0.950 0.884 0.832 1-1/2 ..... ..... ..... ..... ..... 1.187 1.120 1.069 NOTE: *Assuming driven head is flat with diameter and depth of 1.4 and 0.5 respectively, times original rivet diameter. This vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy if metric tools must be used, but Utilimaster does not warrant metric values given in this manual. Rivet diameter, mm. 1.59 2.38 3.18 2.38 4.76 6.35 7.94 9.53 Hole diameter, mm. 1.70 2.44 3.26 2.44 4.85 6.53 8.20 9.80 51 41 30 21 11 F P W ..... ..... ...... ..... Drill no. Rivet length, mm. 1.59 Maximum rivet grips for given lengths in mm* 2.794 2.311 1.549 0.838 6.35 4.166 2.835 3.048 2.388 1.626 ..... ..... ..... 4.76 5.537 5.334 4.572 3.886 3.15 1.575 ..... ..... 9.53 6.909 6.858 6.071 5.436 4.614 3.099 1.575 ..... 11.11 ..... 8.382 7.544 6.985 6.198 4.623 3.099 1.702 12.70 ..... 9.881 9.093 8.484 7.747 6.096 4.597 3.150 14.29 ..... 11.405 10.566 10.033 9.246 7.620 6.121 4.674 15.88 ..... ..... 12.065 11.582 10.770 9.144 7.595 6.198 19.05 ..... ..... 15.088 14.656 13.843 12.116 10.566 9.144 22.23 ..... ..... ..... 17.704 16.891 15.113 13.564 12.090 25.40 ..... ..... ..... ..... 19.939 18.161 16.510 15.138 31.75 ..... ..... ..... ..... ..... 24.130 22.454 21.133 38.10 ..... ..... ..... ..... ..... 30.150 28.448 27.153 NOTE: *Assuming driven head is flat with diameter and depth of 1.4 and 0.5 respectively, times original rivet diameter. 24 Canada Post Body Service Manual 2.4 Torque Values NOTE: These torque values are only suggested values. Specific Utilimaster instructions override these values. Note also that this vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy if metric tools must be used, but Utilimaster does not warrant metric values given in this manual. English Measurements Bolt Size S.A.E. Grade 2 S.A.E. Grade 5 S.A.E. Grade 8 Load** (lbs) Torque* (Ft•Lb) Load** (lbs) Torque* (Ft•Lb) Load** (lbs) Torque* (Ft•Lb) 1/4-20 1/4-28 1,300 1,500 5 6 2,000 2,300 8 10 2,850 3,250 12 14 5/16-18 5/16-24 2,150 2,400 11 13 3,350 3,700 17 19 4,700 5,200 24 27 3/8-16 3/8-24 3,200 3,600 20 22 4,950 5,600 30 35 6,950 7,900 45 50 7/16-14 7/16-20 4,400 4,900 30 35 6,800 7,550 50 55 9,600 10,700 70 80 1/2-13 1/2-20 5,850 6,550 50 55 9,059 10,200 75 85 12,800 14,400 105 120 9/16-12 9/16-18 7,550 8,350 70 80 11,600 13,000 110 120 16,400 18,300 155 170 5/8-11 5/8-18 9,300 10,500 100 110 14,500 16,300 150 170 20,300 23,000 210 240 3/4-10 3/4-16 13,800 15,400 170 190 21,300 23,800 270 300 30,100 33,600 375 420 7/8-9 7/8-14 11,400 12,600 165 180 29,500 32,400 430 475 41,600 45,800 610 670 1”-8 1”-12 1”-14 15,000 16,400 16,800 250 270 280 38,700 42,300 43,300 645 705 720 54,600 59,700 61,100 910 1,000 1,015 * Torque listed are suggested values on parts carrying residual oil of manufacture. These values do not apply to plated or otherwise lubricated parts. ** Clamp load (lbs.) equal to 75% of bolt Proof Load. Reprinted from 1969 S.A.E. Handbook. Canada Post Body Service Manual 25 Metric Equivalents Bolt Size S.A.E. Grade 2 S.A.E. Grade 5 S.A.E. Grade 8 Load** (Kg.) Torque* (N•m.) Load** (Kg.) Torque* (N•m.) Load** (Kg.) 1/4-20 1/4-28 Torque* (N•m.) 5,783 6,673 6 8 8,897 10,231 10 13 12,678 14,457 16 19 5/16-18 5/16-24 9,564 10,676 14 17 14,902 16,459 23 25 20,907 23,131 32 36 3/8-16 3/8-24 14,235 16,014 27 29 22,019 24,910 40 47 30,916 35,141 61 67 7/16-14 7/16-20 19,573 21,797 40 47 30,248 33,585 67 74 42,703 47,596 94 108 1/2-13 1/2-20 26,023 29,136 67 74 40,297 45,372 101 115 56,938 64,055 142 162 9/16-12 9/16-18 33,585 37,143 94 108 51,600 57,827 149 162 72,951 81,403 210 230 5/8-11 5/8-18 41,369 46,707 135 149 64,500 72,506 203 230 90,299 102,310 284 325 3/4-10 3/4-16 61,386 68,503 230 257 94,748 105,568 366 406 133,892 149,461 508 569 7/8-9 7/8-14 50,710 56,048 223 244 131,223 144,123 583 644 185,046 203,729 827 908 1”-8 1”-12 1”-14 66,724 72,951 74,731 339 366 379 172,147 188,160 192,608 874 955 976 242,873 265,559 271,787 1,233 1,355 1,376 * Torque listed are suggested values on parts carrying residual oil of manufacture. These values do not apply to plated or otherwise lubricated parts. ** Clamp load (lbs.) equal to 75% of bolt Proof Load. 26 Canada Post Body Service Manual 2.5 Body Sealants One-compound polyurethanes are very effective sealants. They remain permanently elastic (less cracking due to shrinkage), they can be painted, and they require no mixing. They bond as well as seal, thus reducing the number of mechanical fasteners needed, and they also reduce noise and corrosion. The following statements provide an overview of what to look for when working with polyurethane sealants: 1. Manufacturer’s Recommendations: Always follow manufacturer’s cautions and recommendations for application, protective clothing, and cleanup. 2. Conditions: Recommended application temperatures are 5º to 37º C. For cold-weather applications, store sealants at approximately 21º C., and remove them just prior to using. Make sure joint is frost-free. 3. Surface: The surface must be clean, dry, free of grease or rust, and of sound quality. Clean the surface with a strong jet of compressed air, sandblast, or solvent. Remove all loose particles. 4. Priming: Usually no priming is required. Since substrate type and uniformity can vary, a preliminary test is recommended. Manufacturers of sealants often have primers available for certain types of surfaces or substrates. Since compatibility between manufacturers is not guaranteed, do not mix and match primers and sealants from different manufacturers.. 5. Application: Cut the tip of the plastic nozzle to fit the joint to be sealed. Puncture the airtight seal on the sealant container. Apply sealant with a hand- or power-operated caulking gun. Dip the Poly-stick in a soapy solution to make it easier to seal any gaps in the adhesive. Limitations: • • • • Since the system is moisture-cured, allow sufficient exposure to air. Do not apply over silicones or apply in the presence of curing silicones. Avoid contact with alcohol or alcohol-containing solvents during cure. For best results, use open sealant containers in the same day. Canada Post Body Service Manual 27 3.0 Windows WARNING: A properly bonded windshield is critical to the structural integrity of the vehicle. Utilimaster recommends professional automotive glass specialists replace the windshield and windows. 3.1 Windshield and Quarter-Windows CAUTION: Glass adhesives and sealants have a short shelf life. Close attention must be paid to cleaning surfaces and to timing during installation. The following information can be shared with auto glass shops. NOTE: Please read entire procedure before working on the vehicle. NOTE: If you do the job yourself, you will need: • Replacement glass • Rubber trim molding • Glass replacement tools • Glass cleaner, primer, adhesive materials • The items listed in Sections 3.1.1 and 3.1.2 3.1.1 Tool Kit (Part Number 23005014) The Utilimaster bonded window replacement tool kit (see Illustration 3–1) consists of: • • • • • Illustration 3–1 Tool Kit 28 Windshield support block Quarter-window spacer block Poly-stick Utility knife Window removal tool Not included—masking tape, caulking gun, medium red Scotch Brite™ to roughen surfaces, clean cotton rag or lint-free paper towel, a wooden block (approximately 5 cm x 10 cm x 15 cm) to square glass surface flush with the moulding, and a squeegee or roller is useful for bonding the trim. Canada Post Body Service Manual 3.1.2 Replacement Material Kit (Part Number 23005015) The Utilimaster bonded window replacement material kit (see Illustration 3–2) consists of: • • • • Isopropyl alcohol Sika® Activator Sika® Primer 210T SikaTack® Ultrafast Urethane Adhesive SealantSika® Cleaner 226 Not included—Kent Liquid Rubber 10240 or equivalent to fill in any gaps in the trim seam. Illustration 3–2 Material Kit 3.1.3 Replacement Glass In addition to tools, adhesives, and sealants, you will need to order replacement glass and perimeter trim molding from Utilimaster. (See also the Canada Post Body Parts Manual for replacement parts.) The windshield glass is 6.35 mm-thick laminated safety glass. The quarter-window glass and the glass in sliding doors are tempered safety glass which cannot be cut after tempering. For replacing the entire windshield, about 6.5 meters of perimeter trim molding and 1 meter of flat center trim are required. If care is taken in removing the glass, only the replaced half of the windshield needs to have new molding applied. Each quarter-window glass replacement requires about 2.75 meters of perimeter trim molding. Canada Post Body Service Manual 29 WARNING: Use extreme care when handling glass! WARNING: To avoid injuring yourself or others, use caution when using the window removal tool. 3.1.4 Removal and Replacement Procedure 3.1.4.1 Removing the Glass 1. From the outside of the vehicle, insert the blade of the window-removal tool through the urethane sealant and work your way around the window, cutting the sealant. (After pushing the blade into the sealant use the other hand, pull the tool toward you. See Illustration 3–3.) To avoid injuring yourself or others, be very careful while using the tool! Try to leave at least a 4 mmthick section of sealant on the window frame. NOTE: Remove the side mirror for better access when replacing the quarter glass. Illustration 3–3 Cutting Old Sealant 2. Carefully remove the damaged glass. 3. Check the replacement window for fit. 3.1.4.2 Preparing the Mounting Surface 1. If the old adhesive is bonded firmly to the frame and can not be peeled from the surface, trim the bead down to 2 to 4 mm (see Illustration 3–4). If the old adhesive is loose, remove all adhesive down to the metal surface. NOTE: Trim normally comes off with the window. The only location where there may be a problem is at the center post. 2. Use Scotch Brite™ (medium-red) to roughen the surface of any bare metal area of the mounting flange. Clean the aluminum bond area with isopropyl alcohol. (Do not use lacquer thinners or mineral spirits.) Illustration 3–4 Trimming Sealant Bead 3. Apply Sika® Activator to the exposed metal of the mounting frame using a clean cotton rag or lint free paper towel and wiping in one direction. Turn rag several times to avoid transferring dirt and oil. Drying time is 10 minutes. 4. Brush a light coat of Sika® Primer 210T on the bonding surface. Drying time is 10 minutes. 30 Canada Post Body Service Manual 4-1/8" (10.5 cms) 3/4" (19 mm) 4-3/8" (11.1 cms) 7/8" (22 mm) 3/16" (4.8 mm) 2-1/4" (5.7 cms) Support Blocks Illustration 3–5 Dimensions of Windshield Glass Support Block Illustration 3–6 Placement of Windshield Glass Support Blocks 3.1.4.3 Preparing the Window Glass 1. For windshield replacement, obtain the nylon block available from Utilimaster as glass supports when installing the new windshield glass, or cut a minimum of two (2) wood windshield support blocks. (See Illustration 3–5.) 2. Set the support blocks (beveled edge down) into the trough at the bottom of the windshield, spacing them along the bottom of the opening. (See Illustration 3–6.) 3. For quarter window replacement, obtain the nylon blocks available from Utilimaster to establish the 5/16" (7.9 mm) gap between the glass and frame, or cut one (1) wood quarter window spacer block. (See Illustration 3–7.) 4. Set the spacer block on the flange around the window mount (see Illustration 3–8) and tape to secure (see Illustration 3–9). 5. Clean the glass with a two-to-one mixture of isopropyl alcohol and water. Avoid heavy soaps or ammonia. Auto glass replacement dealers also have recommended cleaners. 6. Apply Sika® Activator to the mounting frame using a clean cotton rag or lint free paper towel and wiping in one direction. 1" (2.5 cm) 7/16" (11 mm) 1/4" (6.4 mm) 5/16" (7.9 mm) 4" (10 cm) 5/16" (7.9 mm) 1" (2.5 cm) 1/4" (6.4 mm) 7/16" (11 mm) Illustration 3–7 Dimensions of Quarter Window Spacer Block Canada Post Body Service Manual 31 7. Wipe the bonding (frit band) area of cleaned glass with Sika® Activator, using a clean cotton rag or lint free paper towel and wiping in one direction. Turn rag several times to avoid transferring dirt and oil. Drying time is 10 minutes. Quarter Window Spacer Block (locate in either of two positions) NOTE: Glass purchased from Utilimaster should have a black ceramic frit band around the perimeter of the mounting side of the glass. If you purchased the glass locally, and there is no frit band, mask off a 2.5 cm-wide area around the perimeter of the mounting side of the glass. Apply Sika® Primer 206 G & P to glass perimeter as a UV block. Drying time is approximately five minutes. (See Illustration 3–10.) 3.1.4.4 Installing the Window Glass 1. Using a caulking gun, apply a bead of Sika® urethane adhesive (approximately 8 mm wide by 13 mm tall) directly to the glass frit band or the mounting flange. Use a “V” shaped nozzle for the optimal bead shape. (See Illustration 3–10.) Illustration 3–8 Location of Quarter Window Spacer Block 2. Close any voids at corners or elsewhere in the sealant bead by smoothing over with a Poly-stick. 3. Install the glass onto the frame and align to the correct position using the support blocks. Use a block to level the outer glass surface with the edge of the molding. NOTE: Glass must be installed within 10 minutes of applying the adhesive to ensure a good bond. Illustration 3–9 Secure Quarter Window Glass Spacer Block 4. Press gently around the entire perimeter of the glass to make good adhesive contact. (See Illustration 3– 11.) Use the Poly-stick to clean up any excess adhesive. Adhesive NOTE: Recommended minimum thickness of the adhesive layer after installation is 7 mm. 5. The quarter-window can be held in place with masking tape until the adhesive sets up. Frit Band 6. Allow at least eight hours for the adhesive to set up when installing a windshield or a quarter-window. NOTE: Windshield installations must have a full bead of adhesive in the center section between the two glass panels. (See Illustration 3–12.) 32 Illustration 3–10 Frit Band and Adhesive Canada Post Body Service Manual Illustration 3–11 Installing Glass Exterior Side Centerpiece of Windshield Structure Windshield Glass Panels Interior Side Windshield Adhesive Illustration 3–12 Cross-section of Windshield Centerpiece. 3.1.4.5 Installing the Trim Molding 1. After the adhesive has dried, scrape any excess adhesive from glass edges and surface with a utility knife and clean with isopropyl alcohol. (Spray 70% to 90% isopropyl alcohol solution around perimeter of glass and wipe dry with a lint free paper towel.) 2. With a paper towel, apply Sika® Cleaner 226 onto the glass around the trim bonding surface and let dry for five minutes. 3. Avoid touching the adhesive while removing the adhesive backing strip. Apply the self-adhesive trim as shown in Illustrations 3–13 through 3–16. Avoid stretching the trim. 4. Miter-cut corners and overlap the trim. Take care to hold the knife with the cutting edge pointing away from you as shown in Illustration 3–15. Do not cut through the lip of the trim—allow it to wrap around the edge of glass. 5. On the quarter-window seam, miter-cut the corners and the angles as shown in Illustration 3–16. 6. The wide flat trim for the center of the windshield should be placed square against the top trim. Check how well the trim will fit before applying the trim to the glass. Canada Post Body Service Manual 33 CAUTION: Be sure not to nick or cut the glass when installing the trim. This damage can lead to cracks developing in the glass. 7. Press down on the center windshield trim using a roller or squeegee to ensure a good bond. Repeat a second time. Cut the bottom end of the center trim square with the bottom trim. 8. If there are any gaps in the mitered seams and joints, fill the seams and joints with liquid rubber. 9. If the quarter-window trim interferes with remounting the mirror bracket, cut just enough lip off the trim to allow the bracket to fit. 3.2 Side Door with Sliding Window 3.2.1 Sliding Window 3.2.1.1 Removal 1. Remove the monobolts around the sliding window. (See Section 2.2.3.) 2. Lift out the window. 3. Scrape off the old foam tape from the door panel. 3.2.1.2 Replacement 1. Place the replacement window in the door frame and from the inside, mark the rivet holes around the circumference of the replacement window. Illustration 3–13 Applying Trim 2. Drill holes into the replacement window frame for the monobolt fasteners. 3. Line the exterior opening on the door with foam tape. 4. Place the new window into the opening. 5. Attach the window to the door frame using monobolt rivets. Illustration 3–14 Applying Trim CAUTION: Do not wash the window or the vehicle for at least 24 hours following application of the window trim. 34 Canada Post Body Service Manual Illustration 3–15 Trimming Corners Peel trim back and discard this piece. Application direction. Place razor blade corner to corner for mitre and cut. Discard. Discard. On all corners except starting and stopping points, don’t cut through the lip of the trim. Keep attached and wrap around corner of glass. Start here. Illustration 3–16 Trim Diagram Canada Post Body Service Manual 35 Sliding Window WARNING: Use extreme care when handling glass! Exterior Door Panel 3.2.2 Lower Side Door Window 3.2.2.1 Removal 1. Remove the old window and the window rubber. Window Rubber 2. Remove any adhesive that may still remain from the ends of the window rubber. 3. Clean the aluminum around the window area with a two-to-one mixture of isopropyl alcohol and water. Turn the rag several times to avoid transferring dirt and oil. Door Frame Door Seal Lower Side Door Window Interior Door Panel Illustration 3–17 Sliding Side Door Windows 3.2.2.2 Replacement 1. Cut a 2.29 m length of window rubber and fit it around the metal frame on which the window is to be installed. Trim off any excess. (See Illustration 3–19.) 2. Using a caulking gun, apply a bead of urethane adhesive inside the window channel to provide an extra seal for the window. (See Illustration 3–19.) 3. Pull back the window rubber locking lip and set the replacement window into the frame. 4. Using a sealing tool, seal the window into the rubber lock by folding the long locking lip under the short lip (nearest the window). (Illustrations 3–20 and 3–21.) 5. Apply a bead of urethane adhesive to the ends of the window rubber to complete the window seal. (See Illustration 3–18.) Illustration 3–18 Trim Ends Sealed with Urethane Adhesive 36 Canada Post Body Service Manual 3.3 Side Door with Roll-up Window 3.3.1 Glass This side faces the inside of the vehicle. Frame channel 3.3.1.1 Removal 1. Remove the door and place on a flat padded surface (with interior side up). (See Section 5.3.3.) NOTE: Keep window rolled down until instructed otherwise. Apply adhesive inside window channel. Short locking lip Long locking lip 2. Remove the two screws from the front guide. (See Illustration 3–22.) 3. Pull the strip glass channel out of the front guide only. Illustration 3–19 Lower Window Trim 4. Remove the front guide from the door and set aside. 5. On the regulator access plate, loosen one screw and remove the second screw. 6. Roll the window up until two (2) screws are visible in the regulator plate access. 7. Remove these two (2) screws. 8. Remove glass (if not completely broken out) by tipping forward and pulling upward out of the opening. Illustration 3–20 Window Trim Sealing Tool NOTE: To remove any broken glass fragments from the bottom of the door continue on with the next steps. Otherwise, go to Section 3.3.1.2. 9. With a Torx® bit, remove the window crank handle, spring, and spacer. 10. With drill and #11 bit (or 3/16" [5 mm]) remove the thirty-two (32) aluminum Magna-Lok® fasteners. 11. Remove the interior door panel. 12. Remove any broken glass fragments from the bottom of the door. Illustration 3–21 Locking the Window Trim Canada Post Body Service Manual 37 WARNING: Use extreme care when handling glass! 3.3.1.2 Replacement Replace the glass by reversing the above process. If steps 9 through 13 are followed, also refer to the window regulator replacement procedure in Section 3.3.2. 3.3.2 Window Regulator 3.3.2.1 Removal Front Guide Door Seal Access Plate Crank Handle 1. Remove the door, and place it on a padded surface (interior side up). (See Section 5.3.3.) 2. Loosen both screws to the regulator access plate. (See Illustration 3–22.) 3. Roll window up until the two (2) screws are visible in the regulator access plate. Illustration 3–22 Driver’s Sliding Door 4. Remove these two (2) screws. 5. Push glass into the up position. 6. With a Torx® bit, remove the window crank handle, spring, and spacer. 7. Remove the six (6) Phillips-head screws holding the regulator. 8. With drill and #11 bit (or 3/16" [5 mm]) remove the thirty-two (32) aluminum Magna-Lok ® fasteners. 9. Remove the interior door panel. 10. Remove the two (2) pan-head screws holding the regulator to the window assembly. (See Illustration 3–23.) 38 Canada Post Body Service Manual 3.3.2.2 Replacement 1. Fasten the new regulator to the window assembly with two (2) pan-head screws. 2. Place the interior door panel on top of the door. 3. Fasten the replacement regulator to the interior door panel with six (6) Phillips-head screws. Torque to 35–45 in•lb (4–5 N•m). 4. Install thirty-two (32) Magna-Lok fasteners in the predrilled holes of the interior door panel. 5. Adjust the regulator until holes are accessible through the access plate. 6. Slide the window down and secure to the regulator with two (2) screws. Illustration 3–23 Regulator 7. With the same two (2) screws visible through access, align the window crank handle in a horizontal position with the knob toward the rear of the vehicle. (See Illustration 3–22.) 8. Mount the window crank handle, spring, and spacer with the Torx® bit in this position. 9. Secure the access plate with two (2) screws. 10. Reinstall the door into the truck. (See Section 5.3.4.) Canada Post Body Service Manual 39 4.0 Wiper/Washer System CAUTION: The wiper motor is equipped with an internal thermal overload protection switch that stops the wiper motor in case of overload. If the motor is not unplugged, the motor may activate itself without warning. Always unplug the motor when working on or disconnecting wiper linkages. Motor Bracket Motor Wiper Blade Pivot Wiper Arm CAUTION: Always use the correct wiper harness plug and wiper switch when bench-testing a motor. Accidental hot wiring of the wrong wiper motor terminal may cause damage to the internal components of the wiper motor. Washer Bottle CAUTION: Always install wiper arms and blades according to manufacturer’s instructions to avoid interference with the windshield molding. Illustration 4–1 Wiper/Washer System 40 Canada Post Body Service Manual 4.1 Wiper System Troubleshooting Procedure The following troubleshooting and repair procedure should be followed when encountering problems with wiper systems. CONDITION CORRECTIVE ACTION 1. Wiper motor inoperative high or low speed. Fuse Okay? No Remove and replace wiper switch. Remove and replace fuse. Yes Power available at high and low speed terminal of motor connector? Yes No Power available at high and low speed wiper switch terminals? No Yes Yes No Repair open circuit between wiper switch and wiper motor connectors. Remove and replace wiper motor. Power available from ignition switch to wiper switch? Repair open circuit between ignition and wiper switch connectors. 2. Wiper motor runs, but wiper arms do not move. Motor crank broken or loose? No Yes Linkage moves freely when disconnected from motor shaft? No Remove and replace linkage and/or pivot assembly. No Remove and replace wiper switch. Yes Check motor shaft splines for damage and replace damaged parts. Remove and replace wiper motor. 3. Wiper motor inoperative at low speeds. Power available at low speed terminal of motor connector? Yes Remove and replace wiper motor. Canada Post Body Service Manual No Power available at low speed terminal of wiper switch connector? Yes Repair open circuit between wiper switch and wiper motor connectors. 41 4. Wiper motor inoperative at high speed. Power available at high speed terminal of motor connector? No Power available at high speed terminal of wiper switch connector? Remove and replace wiper switch. Yes Yes Remove and replace wiper motor. No Repair open circuit between wiper switch and wiper motor connectors. 5. Wipers operational but do not return to park position. Power available at park terminal of wiper motor connector? No Repair open circuit between wiper switch and wiper motor connectors. Yes Remove and replace wiper motor. 6. Wipers operational but do not return to park position. Wiper motor crank in the correct park position? No Yes Remove wiper motor crank, check motor shaft for damaged splines, replace damaged parts, and reinstall crank in the correct park position. Remove wiper motor crank, check motor shaft for damaged splines and replace damaged parts. Run motor and park. Reinstall wiper arms in correct park position, and torque to 16.5 N•m. 7. Wipers oversweep or undersweep. Park position of wiper arms correct? No Correct park position of wiper arms and/or wiper motor crank. Yes Check for loose or worn linkage, excessive play in pivot shaft assembly, and replace damaged parts. See the Coupler Addendum on the next page. 42 Canada Post Body Service Manual Coupler Addendum for Wiper System Troubleshooting Procedure Wiper Oversweep or Undersweep. Park Position of Wiper Arms OK? No Correct Park Position of Wiper Arms and/or Motor Crank. Yes Coupler loose? No Coupler Check for Other Loose/Worn Linkage, Excessive Play in Pivot Shaft Assemblies , and Replace Damaged Parts as Necessary. Yes Torque Screw to 12.5-13.5 N•m or Replace Linkage. Canada Post Body Service Manual 43 4.2 Wiper Motor 4.2.1 Removal 1. Disconnect the battery negative (black) cable. 2. Disconnect the electrical connector from the wiper motor. 3. Remove the wiper motor drive shaft nut with a 13 mm wrench. (See Illustration 4–2.) 4. Remove the motor crank from the motor drive shaft. 5. Remove the three motor mount screws with a 10 mm wrench. 6. Remove the wiper motor. Motor Crank Motor Drive Shaft Nut (Use 13 mm Wrench) Torque to 12.2–23 N•m 4.2.1 Replacement Motor Mount Screw (Use 10 mm Wrench) Torque to 9.1–15 N•m Illustration 4–2 Motor Mount and Crank 1. Replace the motor mount screws and torque to 6.7 to 11.1 ft•lb (9.1–15 N•m). 2. Reconnect the wiper harness. 3. Reconnect the negitive (black) battery cable. 4. Turn on the ignition switch and run the wiper system. Turn off the wiper system, this will allow the wiper motor to park itself. 5. With the wiper arms still attached to the pivots, move the wiper arms until the linkage is in the park position. (See Illustration 4–4.) 6. Ensure that the ignition switch is off. 7. Attach the motor drive crank to the motor drive shaft. 8. Torque the motor drive shaft nut 9 to 17 ft•lb (12.2–23 N•m). NOTE: If the wiper linkage moves while torquing the motor drive crank, when the ignition is switched back on, the wiper system will rotate once to park itself. 44 Canada Post Body Service Manual 4.3 Pivot and Link Assembly 4.3.1 Removal 1. Disconnect the battery negative (black) cable. 2. Remove the head covers. (See Illustration 4–6.) 3. Remove the arm retaining nuts with a 14 mm wrench, and remove the washers and wiper arms. 4. Remove the wiper arms. See Section 4.5. 5. Remove the 1-1/8" (29 mm) locknuts and washers from the pivot assemblies. (See Illustration 4–6.) 6. Remove the wiper motor drive shaft nut with a 13 mm wrench. (See Illustration 4–7.) Illustration 4–3 Rain Shield 7. Remove the motor crank from the wiper motor drive shaft. (See Illustration 4–2.) 8. Remove the pivot and link assembly. Pivot Cranks Motor and Bracket Assembly Links Illustration 4–4 Park Position Section of Arm Head Head Cover Rain Shield Washer This nut does not move 1-1/8" Locknuts Illustration 4–6 Pivot Assembly Canada Post Body Service Manual 45 Motor Crank Motor Drive Shaft Nut Illustration 4–7 Motor Crank 4.3.2 Replacement 1. Position the system linkage assembly and push pivots through 0.81" (20.5 mm) holes in the body. 2. Assemble pivots as follows: (a) Place a steel washer onto each pivot body. (See Illustration 4–8.) (b) Place a 1-1/8" (29 mm) locknut onto the pivot assembly, torque from 22 to 30 ft•lb (30 to 40 N•m). (c) Place a rain shield onto the pivot body. (See Illustration 4–3.) 3. Reconnect the battery, turn the ignition on, and run the wiper system. Return the wiper control to the OFF position to allow the wiper motor to park itself. 4. Disconnect the battery. Reinstall the motor crank to the wiper motor drive shaft, and torque the motor drive shaft nut from 9 to 17 ft•lb (13 to 23 N•m). (See Illustration 4–7.) 5. Reconnect the battery, turn the ignition on, and run the wiper system. Return the wiper control to the OFF position to check for the correct park position. In the correct park position, the pivot cranks should be positioned as shown in Illustration 4–9. 6. Replace the wiper arms on the pivot assembly as described in Section 4.5. 7. Start the wiper system and test all the functions. 1-1/8" Locknut Pivot Body 1-1/8" Locknut Washer This nut does not move Rain Shield Torque to 22 to 30 ft•lb (30 to 40 N•m) with a 1-1/8"(29 mm) Deep Well Socket Illustration 4–8 Pivot Replacement 46 Canada Post Body Service Manual Pivot Cranks Illustration 4–9 Park Position 4.4 Wiper Blade Assembly 4.4.1 Removal 1. Pull the wiper arm away from the windshield, and lock the arm into the service position. 2. Rotate the blade about 90°, and push the blade toward the windshield about 2.5 cm. (The rubber insert will bow outward from the arm pushing against it.) (See Illustration 4–10.) 3. Unhook the blade assembly from the arm. 4.4.2 Replacement 1. Hook in a new blade, and push the blade away from the vehicle until the blade locks in place. 1. To remove, lock arm in the service position 2. Rotate the new blade to its normal position, and lower the arm. Plastic Retaining Clip End of wiper arm assembly 3. Slide arm hook out of blade assembly 4.5 Wiper Arms 4.5.1 Removal 2. Push wiper blade assembly toward the windshield 1. Disconnect the washer jet hoses. 2. Remove the head covers. (See Illustration 4–11.) Illustration 4–10 Installing Wiper Blade Assembly 3. Remove the arm retaining nuts with a 14 mm wrench, and remove the wiper arms. 4.5.2 Replacement 1. Ensure the wiper system is PARKED with pivot cranks as shown. (See Illustration 4–12.) 2. Push the arm heads over the tapered knurl shaft with the arms facing outwards from the center of the windshield at park position. (See Illustration 4–14.) The blades should be approximately 10 cm from the bottom of the windshield glass to the outer end of the blade tip. (See Illustration 4–13.) 3. Replace the two arm retaining nuts, and torque them 14.8 to 16.2 ft•lb (20.5 to 21.5 N•m.) with a 14 mm wrench. 4. Push the washer jet hoses through the holes provided in the body, and connect them to the washer pump. 5. Replace the head covers over the retaining nuts on the arm heads. (See Illustration 4–14.) Canada Post Body Service Manual 47 4.6 Pivot Assembly Section of Arm Head Note: The pivot and link assemblies are supplied as a complete unit. When a pivot becomes worn through age, the linkage is also often worn. Therefore, the complete pivot and linkage assemblies should be replaced. The Manufacturer and/or Utilimaster Corporation will not warrant pivots or Head links, supplied and installed as separate components, that fail Cover due to poor or incorrect installation. Rain Shield 4.6.1 Removal 1. Disconnect the battery negative (black) cable. 2. Remove the head covers. (See Illustration 4–14.) 3. Loosen and remove the two arm retaining nuts with a 14 mm wrench, and remove the wiper arms. 4. Disconnect the link from the pivot by applying even pressure, using two flat-bladed screwdrivers, on the underside of the plastic ball cap. (See Illustration 4–15.) Arm Retaining Nut Illustration 4–11 Removing Wiper Arm 5. Remove the rain shield. 6. Remove the 1-1/8" (29 mm) AF locknut from the pivot. 7. Remove the pivot assembly. Pivot Cranks Motor and Bracket Assembly Links Illustration 4–12 Park Position 4.6.2 Replacement 1. Set the replacement pivot assembly in place. 2. Replace the 1-1/8" (29 mm) AF locknut and torque from 22 to 30 ft•lb (30 to 40 N•m). 3. Grease the plastic ball cap with Castrol “LM” or Shell “Retinax A” grease or equivalent. 4. Place a 3/4" socket over the plastic ball cap, and push the cap onto the pivot ball. Using a pair of multigrips or tongue-and-groove pliers, squeeze the socket and the pivot crank together until the ball is firmly seated in the ball cap. (See Illustration 4–16.) 5. Replace the rain shield. 6. Reconnect the battery, turn the ignition on and run the wiper system. Return the wiper control to the OFF Position to allow the wiper motor to park itself. 7. Replace the wiper arms on the pivot assembly as described in Section 4.5. 48 Canada Post Body Service Manual 10 cm Illustration 4–13 Park Position Section of Arm Head Tapered Knurl Shaft Head Cover Pivot Body Arm Retaining Nut Illustration 4–14 Head Cover Arm Retaining Nut Rain Shield 1-1/8"AF Locknut Pivot Assembly Flat blade Screwdriver Link Plastic Ball Cap Illustration 4–15 Pivot Assembly Pivot Crank Pivot Assembly Pivot Ball Link 3/4" (19 mm) Socket Pliers Illustration 4–16 Squeezing Socket and Pivot Crank Canada Post Body Service Manual 49 4.7 Washer Bottle 4.7.1 Removal 1. Unscrew the four (4) Torx® screws that hold the bottle to the floor, and set aside the screws and the washer bottle for later use. 2. Detach the fluid hose and wire harness plug from the washer bottle. 4.7.2 Replacement 1. Attach the fluid hose and wire harness plug to the washer bottle. (See Illustration 4–17.) Illustration 4–17 Connect Hose and Wire Harness 2. Fasten bottle to the floor with four (4) Torx screws and washers. (See Illustration 4–18.) Illustration 4–18 Mount Bottle to Floor 50 Canada Post Body Service Manual 5.0 Doors 5.1 Keys 5.1.1 Ignition Keys Ignition keys are supplied by Ford. They can be duplicated in most hardware stores, or by contacting Ford (or Utilimaster) for more information. 5.1.2 Other Keys Keys to the rear roll-up door, and bulkhead door are supplied by Best Access Systems. Contact: Best Access Systems 6150 E. 75th street Indianapolis IN 46250 Phone: 317-849-6930 Fax: 317-845-7649 Illustration 5–1 Cargo Access, Door Access and Ignition Keys Important! Record the key number stamped on the key for each truck. For security reasons they are usually not stamped on the lock cylinder, and you must have this number to obtain replacement keys. Units are produced with one lock cylinder option. To maintain security control, you should contact the lock company directly for replacements. Order locks by faxing an order on Canada Post letterhead. Include the following information: Your Name Employee Number Complete Mailing and Billing Address Phone Number Key Code and Amount Requested Canada Post Body Service Manual 51 5.2 Rear Roll-Up Door WARNING: The counterbalance spring is wound under high tension. This high-tension spring can cause severe injury or death. Only qualified technicians should adjust this spring. • Installation, repairs, and adjustments must be made by trained service personnel using proper tools and instructions. • Use two winding bars that are 1/2" (12.7 mm) in diameter and 46 cm long. DO NOT USE bent winding bars, screwdrivers, or punches for spring winding. Illustration 5–2 Location of Serial Number on a Todco Roll-Up Door NOTE: When ordering parts for a rear door, specify the serial number of the door. The serial number can be found on the metal tag attached to the inside upper left-hand corner of the door (when standing inside the cargo area, facing the door). NOTE: After replacement of any part, check relevant adjustments and proper operation of the door. WARNING: Read all instructions before starting repair. Always maintain firm footing and control of tools. 52 Canada Post Body Service Manual 5.2.1 Cable Replacement Procedure (With Tension On Spring) Right hand cable drum must be tight against bearing Left hand cable drum must be tight against bearing Spring Anchor Plug Spring Winding Plug Cable Door Top Panel Chalk mark Spring Anchor Bracket Roadside Curbside Counterbalance shown inside looking outside Illustration 5–3 Counterbalance Mounting Details 5.2.1.1 Removal NOTE: If only one cable is frayed or damaged, Utilimaster still recommends that both cables be replaced at the same time. 1. Close the door from the inside. Release the spring tension from the cables by fully inserting a winding bar that is 1/2" (12.7 mm) in diameter and 46 cm long into one of the spring-winding-plug holes. (See Illustrations 5–3 and 5–5.) 2. Raise the bar enough to allow insertion of a second winding bar into the lower hole, and release the tension enough to let the second bar rest against the top panel. 3. Loosen the two setscrews on the cable drum, releasing the cable drum from the shaft, and remove the cable from the cable drum. 4. Remove the cable from the door bottom panel by removing the anchor and cotter pins. (See Illustration 5–4.) Canada Post Body Service Manual WARNING: DO NOT raise the door with the winding bar in place. Raising the door at this point can cause injury or damage to equipment. Cable Cable Anchor Bracket Cotter Pin Cable Anchor Pin Exterior View of Door Illustration 5–4 Cable Anchor 53 Ceiling Spring Anchor Bracket Locking pliers against ceiling Chalk mark Support Bracket Turns 12.7 mm diameter x 46 cm Winding Bar 12.7 cms for spring growth To loosen spring Wind towards ceiling Illustration 5–5 Counterbalance Winding Details 5.2.1.2 Replacement 1. Mount the new cable at the base of the bottom panel by slipping the cable anchor pin through the cable anchor bracket and the eye at the end of the cable. 2. Insert the cotter pin in the cable anchor pin to secure the cable. 3. Bring the other cable end to the top of the door and thread it over the top of the door to the inside. 4. Temporarily tape the cable to the outside top panel of the door. 5. From inside the cargo area, insert the cable end into the cable drum slot. Thread the cable into the groove nearest the slot, and turn the cable drum toward you until all slack is taken out, making sure the cable is following in its proper groove. NOTE: The cable must be wound from the outermost groove toward the inside of the drum. 6. Maintaining tension on the cable, slide the cable drum on the counterbalance shaft 54 against the bearing, and tighten the two setscrews on the drum. NOTE: Make sure the drums are against the counterbalance shaft bearings, the set screws are properly tightened, and the cables have equal tension. 7. Clamp the counterbalance shaft with a locking pliers, handle against the ceiling to keep the cables tight. (See Illustration 5– 5.) 8. Release the spring tension by rotating the spring winding plug just far enough to allow removal of the winding bar against the top of the door. NOTE: Rotating the counterbalance assembly too far may cause cables to jump off the cable drum. 9. Remove the clamp, tape, and check the operation of the door. NOTE: A properly adjusted door should open easily and when stopped, it should remain at any given location. (See Section 5.2.2.) Canada Post Body Service Manual WARNING: The counterbalance spring is wound under high tension. This high-tension spring can cause severe injury or death. Only qualified technicians should adjust this spring. • Installation, repairs, and adjustments must be made by trained service personnel using proper tools and instructions. • Use two winding bars that are 1/2" (12.7 mm) in diameter by 46 cm long. DO NOT USE bent winding bars, screwdrivers, or punches for spring winding. Chalk mark Wound chalk mark Illustration 5–6 Mark Spring with Chalk to Keep Track of Winding 5.2.2 Spring Winding Procedure NOTE: A properly adjusted door should, when stopped, remain at any given location. 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 has a tendency to drop when stopped, a few more quarter turns should be added. 1. Close the door and on the inside, clamp the counterbalance shaft with the handle of the locking pliers against the ceiling to keep the cables tight. (See Illustration 5–5.) 2. Run a chalk mark the full length of the counterbalance spring. (See Illustration 5– 6.) 5. Wind the spring by lifting up the bar. While holding the first bar, place a second bar in the next hole, and lift in the same manner after removing the first bar. Repeat for twelve (12) complete turns. Turns are counted by using the chalk marks which show up as stripes as the spring is wound. (See Illustration 5–6.) 6. After adjusting the spring tension, tighten both setscrews on the spring winding plug, and remove the locking pliers from the counterbalance shaft. 7. Check the operation of the door by opening and closing the door. 3. Insert a winding bar that is 1/2" (12.7 mm) in diameter and 46 cm long into one of the spring winding plug holes. 4. Loosen the setscrews on the spring winding plug. Canada Post Body Service Manual 55 5.2.3 Intermediate Panel 5.2.3.1 Removal 1. With the door closed and to prevent the door from raising, clamp the track below the panel to be replaced. 2. Using a 1/4" (6 mm) drill bit, drill off the rivets in the center hinges on the panel to be removed. (See Illustration 5–7.) CAUTION: Take care not to drill through the outside panel. 3. Using a 1/2" wrench, remove both roller brackets and rollers at both joints or top of the panel. (See Illustration 5–8.) NOTE: Punch out the rivet and in at least one of the hinges, insert a punch into one of the rivet holes to stabilize the door panel while detaching the remaining rivets and bolts. Illustration 5–7 Center Hinge 4. Drill off the end hinge rivets attached to the bottom of the panel with a 1/4" (6 mm) drill bit. 5. Lift the door panels above the panel to be replaced into the horizontal track, and secure them with a locking pliers clamped on the horizontal track. 6. Remove the punch and lift out the old panel. 5.2.3.2 Replacement 1. Line up the new panel, and drill all of the hinge holes on the bottom of the new panel. 5. Lower the door from the horizontal tracks, and drill all the holes in the top of the new panel. 2. With the upper door section clamped so that it will not fall, tip the panel toward you to insert the bolts. 6. Insert the bolts and install the hinges over the bolts. Tighten the nuts. 3. Install the hinges over the bolts, and tighten the nuts. 4. Swing the new panel upright and clamp into position. 56 Illustration 5–8 Joint Roller Bracket 7. Remove the clamps and check the door operation by opening and closing the door. NOTE: A properly adjusted door should open easily and when stopped, it should remain at any given location. (See Section 5.2.2.) Canada Post Body Service Manual 5.2.4 Top Panel 5.2.4.1 Removal 1. With the door closed, clamp the track below the top panel to prevent the door from raising. CAUTION: Take care not to drill through the outside panel. 2. Using a 1/4" (6 mm) drill bit, drill out the rivets in the center hinges on the top panel and the rivets on the end hinges at the joint in the lower half of the top panel. (See Illustrations 5–7 and 5–8.) NOTE:Punch out the rivet and in at least one of the hinges, insert a punch into one of the rivet holes to stabilize the door panel while detaching the remaining rivets and bolts. 3 Illustration 5–9 Top Roller Bracket Using a wrench with a 7/16" socket, remove the roller brackets and rollers at the top of the panel. (See Illustration 5–9.) 4. Remove the punch and lift out the old panel. 5.2.4.2 Replacement 1. Line up the new panel, and drill all of the hinge holes on the bottom of the new panel. 2. Tip the panel toward you to insert the bolts through the outside of the panel. 3. Install the hinges over the bolts, and tighten the nuts. NOTE: The roller brackets on the bottom of the top panel and on the top of the bottom panel play an important part in maintaining proper door alignment within the track. The rollers on these brackets must have 3 to 4 spacer washers (depending on the alignment) to maintain the correct distance in the track. (See Illustration 5–10.) 4. Swing the new panel upright and clamp into position. Canada Post Body Service Manual Illustration 5–10 Washers Help Align the Door in the Track. 5. Drill all the holes in the new panel for the top roller bracket. 6. Insert the bolts and install the hinges over the bolts. Tighten the nuts. 57 7. Remove the clamps and check the door operation by opening and closing the door. NOTE: A properly adjusted door should open easily and when stopped, it should remain at any given location. (See Section 5.2.2.) 8. Also check the seal on the outside top of the roll-up door. NOTE: The top panel can be adjusted by loosening the top roller bracket bolt and moving the top roller up or down to adjust the top panel in or out. (See Illustration 5– 11.) 5.2.5 Bottom Panel Move roller up to move panel in. Move roller down to move panel out. Illustration 5–11 Top Roller Bracket Adjustments 5.2.5.1 Removal 1. Open the door and push back until the bottom of the door is about 40 cm or so from the header at the top of the door opening. 2. Place a clamp in the horizontal tracks, on each side, below the bottom rollers. 3. Place a clamp on one of the cables, near the eye of the cable. 4. Grasping the clamp with one hand, release the cable from the bottom of door by pulling the cotter pin out of the cable anchor pin and removing the anchor pin. (See Illustration 5–12.) 5. Allow the spring to wind the cable onto the drum until the clamp stops it by contacting the drum. 6. Repeat with the opposite cable. 7. Using a 1/4" (6 mm) drill bit, drill out two rivets which fasten the pull strap to the strap loop on the parcel shelf. (See Section 5.2.6.) CAUTION: Take care not to drill through the outside panel. 58 Cable Cable Anchor Bracket Cotter Pin Cable Anchor Pin Exterior View of Door Illustration 5–12 Cable Anchor 8. Drill out the center hinge rivets attached to the bottom panel. (See Illustration 5–7.) NOTE:Punch out the rivet and in at least one of the hinges, insert a punch into one of the rivet holes to stabilize the door panel while detaching the remaining rivets and bolts. 9. Using a 1/2" wrench, remove both roller brackets located at the bottom of the bottom panel, and remove the rollers. (See Illustration 5–13.) Canada Post Body Service Manual 10. Using a 1/2" wrench, remove both roller brackets and rollers at the joint or top of the bottom panel. 11. Using a 1/4" (6 mm) drill bit, drill out the end hinge rivets attached to the bottom panel. 12. Remove the panel from the tracks and push the remainder of the door slightly towards the front of the truck. 13. Place a clamp in the track to prevent the door from rolling back down. 5.2.5.2 Replacement 1. Remove a bottom roller bracket from the old panel. 2. Attach the bottom roller bracket on the new panel. 3. Position the new panel and roller in the track. 4. Install the other bottom roller in the track, and align with the bottom roller bracket. Illustration 5–13 Bottom Roller Bracket track. The rollers on these brackets must have 3 to 4 spacer washers (depending on the alignment) to maintain the correct distance in the track. 9. Reattach the pull strap. (See Section 5.2.6.) 5. Attach the assembly to the door using 5/16" nuts and bolts. 10. Reconnect each cable by drawing it by the clamp to the outside of the bottom door panel. 6. Using the hinges as a template and a #11 (3/16" [5 mm]) drill bit, drill rivet holes in the new panel. 11. Insert the cable anchor pin through the cable eye and the cable anchor bracket. (See Illustration 5–12.) NOTE: Make sure the panels align for a close fit at the joint. 7. Rivet the hinges into place. 8. Replace the rollers at the joints, as well as any spacer washers on the roller shafts. (See Illustration 5–10.) NOTE: The roller brackets on the top of the bottom panel and on the bottom of the top panel play an important part in maintaining proper door alignment within the Canada Post Body Service Manual 12. Secure the cable anchor pin with the cotter pin. 13. Remove the clamps and check the door operation by opening and closing the door. NOTE: A properly adjusted door should open easily and when stopped, it should remain at any given location. (See Section 5.2.2.) 59 5.2.7. Seals 5.2.7.1 Brush Seals All brush seals (top and sides) must be replaced at the same time. 1. Open the roll-up door. 2. Remove the rivets that hold the brush seal aluminum strip in place. (See Illustration 5– 15.) 3. Remove the brush seals. 4. Cut the new brushes to the proper length with bolt cutters. Illustration 5–14 Remove Pull Strap Rivets from Roll-up Door 5.2.6 Pull Strap Replacement 1. Open the door enough to allow for comfort while working, and then clamp the track to prevent the door from opening or closing. 2. Drill out the two (2) rivets holding the pull strap to the bottom panel of the roll-up door. (See Illustration 5–14.) 5. Using the old brush seal as a template, drill rivet holes using a #11 (3/16" [5mm]) drill bit. 6. Attach the brush seals and the aluminum strip using aluminum fasteners or stainless steel sheet metal screws. 7. Close the door and check the seals. 3. Attach the end of the new strap to the bottom panel of the roll-up door with rivets or sheet metal screws. 4. Remove the clamp and test the strap while opening and closing the door. Remove the rivets holding the seal strip to the door frame to remove the brush seals. Illustration 5–15 Brush Seals on Rear Roll up Door 60 Canada Post Body Service Manual 5.2.7.2 Bottom Vinyl Seal This seal is held in place by both an undercut design of the panel and seal, and also by fasteners placed through the vinyl seal into the bottom door panel. 1. Open the roll-up door part of the way (with enough clearance to work comfortably) and, to prevent the door from opening or closing, place a clamp in the track . 2. Unscrew and discard the Phillips-head fasteners holding the vinyl seal to the bottom door panel. (See Illustrations 5–17 and 5–18.) 3. Remove the old seal. 4. Install the new seal, angle edge first, and rotate it into position. 5. Secure with nine #8 (or larger) stainless steel flathead screws. Illustration 5–17 Cross-section of Bottom Panel with Vinyl Seal 6. Remove the clamp, close the door and check the seal. Illustration 5–18 Vinyl Seal on the Bottom of the Rear Roll up Door Canada Post Body Service Manual 61 5.3 Side Sliding Doors Track Channel Weather Stripping Rollers Fixed Window Seal Roll-up Window Door Frame Exterior Seal Regulator Bracket Interior Seal Seal Channel Exterior Handle Exterior Door Panel Regulator Crank or Handle Catch Shim Interior Door Panel Interior Handle Access Panel Illustration 5–19 Left-Hand Sliding Side Door (Exploded View) 62 Canada Post Body Service Manual Sliding Window Track Channel Exterior Door Panel Roller Catch Exterior Handle Seal Shim Interior Handle Window Rubber Lower Door Guide Rubber Trim Lower Window Door Frame Interior Door Panel Illustration 5–20 Right-Hand Sliding Side Door (Exploded View) Canada Post Body Service Manual 63 5.3.1 Side Sliding Door Handle Assembly 5.3.1.1 Removal 1. Remove the four (4) two-way 7/16" locknuts on the interior of the door mechanism. Discard the nuts because the locking feature has been destroyed. (See Illustrations 5–19 through 21.) 2. Hardware is loose. Grabbing the interior handle and the exterior handle, pull apart the mechanism. The interior handle, shim and the exterior handle come off. (See Illustrations 5–22 and 5–23.) 5.3.1.2 Replacement 1. Align the exterior handle in the cutout on the door. Illustration 5–21 Unscrewing Handle 2. Align the dot on the bushing with the 3/16" (4.8 mm) square hole (above the lock knob) with the arrow stamped in the lock body. 3. With the shim in place, align the square shafts on the exterior handle with the square openings on the interior handle and push them together. 4. Insert four (4) carriage bolts into the handle from the exterior. 5. From the interior, install four (4) new two-way locknuts. 6. Align the four bolts with the four holes on the exterior of the door. Tighten to 8 ft•lb (10.5 N•m). Illustration 5–22 Removing Inner Handle Illustration 5–23 Removing Outer Handle 64 Canada Post Body Service Manual 5.3.2 Adjusting Side Sliding Door Catch 1. Loosen the two bolts that attach the door catch to the body. (See Illustration 5–24.) 2. Slide the cab door into the closed position. 3. Align the catch with the latch on the door. (See Illustration 5–25.) 4. While holding the catch in position, tighten the two bolts to 7–9 ft•lb (9 to 13 N•m). Illustration 5–24 Loosening the Catch 5. Open and close the door multiple times to ensure proper operation. Repeat the process if necessary. 5.3.3 Side Sliding Door Removal NOTE: Although it is not required, removing the door handle first (see Section 5.4.1) makes removing the door easier. Catch Plate 1/8" (3.2 mm) Latch Tongue Illustration 5–25 Aligning Latch and Catch 1. From the interior use a 7/16" wrench to brace the two-way locknuts in the bottom of the door. From the exterior, unscrew the four pan-head screws with a Phillips-head screwdriver. (See Illustration 5–26.) 2. Remove the lower door guide. (See Illustration 5–27.) 3. From the exterior, locate the two-way locknut under the top black seal, and brace the nut with a 1/2" wrench. (See Illustration 5–28.) From the interior, use a 1/2" socket wrench to loosen the top two bolts and remove. (See Illustration 5–29.) 4. Push the roller assembly back into the door pocket. (See Illustration 5–30.) Canada Post Body Service Manual 65 5. With support from the interior person, the exterior person lifts the door up and out. (See Illustration 5–31.) NOTE: Discard bolts, two-way locknuts, and screws. New screws, and two-way locknuts are required. Illustration 5–27 Removing Lower Door Guide Illustration 5–26 Removing Bottom Screws 5.3.4 Side Sliding Door Replacement NOTE: Refer to Illustrations 5–21 through 5–27 (in reverse order) for the installation of the door. 1. Set the door in the door opening. Illustration 5–28 Locating Locknut 2. Slide the roller assembly into place. 3. From the exterior, lift the door. 4. From the interior, align the front hole on the door with the front hole on the top of the roller assembly. 5. From the interior, quickly insert a new bolt. NOTE: The next step should be performed quickly because the door is very heavy. 6. From the exterior, brace the front of the door and push backwards as the interior person aligns the back hole on the door with the back hole on the top of the roller assembly. Insert a new bolt. 66 Illustration 5–29 Removing Bolts Canada Post Body Service Manual Illustration 5–30 Pushing Back Roller Assembly 7. From the exterior, lift the black rubber seal on the top of the door frame to expose the bolts. 8. Attach the washers and the new two-way locknuts. NOTE: Do not reuse the two-way locknuts, bolts, pan-head screws when replacing the sliding door. 9. From the interior, use a 1/2" socket wrench to tighten the bolts. 10. From the exterior, place the new pan-head screws into the lower door guide at the bottom using the existing holes. 11. From the interior, place the washers and the new two-way locknuts onto the screws and brace with a 7/16" wrench. Illustration 5–31 Removing Door 5.3.5 Sliding Door Exterior Panel 5.3.5.1 Removal 1. Remove the handle. (See Section 5.3.1.) 2. Remove the door from the vehicle. (See Section 5.3.2.) 3. Place on a flat surface. 4. Remove the window. (See Section 3.2.) 5. Remove the rivets using a #11 (or 3/16" [5 mm]) drill bit and drill (be sure to remove all of the rivet). 6. Remove the seal and the extrusion from the back edge of door and set them aside for reuse. 7. Remove the exterior door metal and discard. 12. From the exterior, tighten the screws with a screwdriver. 13. Replace the door handle if necessary. (See Sections 5.3.2 and 5.3.7 for door handle installation and adjustment.) Canada Post Body Service Manual 67 5.3.6 Sliding Door Lower Guide 5.3.6.1 Removal 1. Open the door. 2. Use a #11 (3/16" [5 mm]) drill bit to drill out and remove the small retaining rivet. (See Illustration 5–32.) 3. Slide the plastic lower guide toward rear of vehicle and into the door pocket until it stops. (See Illustrations 5–33 and 5–35.) 4. Close the door. 5. Remove the plastic guide from the underside of vehicle, at the rear of the door pocket. Pull the lower plastic guide down and out of the door pocket. (See Illustrations 5–34 and 5–38.) Illustration 5–32 Remove the Retaining Rivet 5.3.6.2 Replacement 1. Feed the new plastic guide into the door pocket and aluminum retainer extrusion in the reverse procedure of Step 5 above. 2. Open the door. 3. Pull the plastic guide forward to the front edge of the retainer extrusion. Illustration 5–33 Slide Lower Guide 4. Replace the removed retaining rivet with a new rivet. 5.3.7 Adjusting Side Sliding Door 5.3.7.1 Inspection 1. Use an air hose or vacuum along door track and guide to clear out any debris. 2. Note the door action during opening and closing. a. Illustration 5–34 Guide Beneath the Truck If the door moves in or out as it engages the catch, adjust the catch. (See Section 5.3.2.) b. If the top of the door is out of line with the bottom, adjust the upper door guide (see below). c. If the door is loose or catches at the bottom, adjust the lower door guide (see below). 3. Check the door action and adjust until it is smooth. Rear of the door should not raise during closing. The door front should not raise while opening. 68 Canada Post Body Service Manual 5.3.7.2 Adjusting Upper Door Guide (In and Out) 1. Loosen the five nuts holding the upper door track to the door jamb. (See Illustration 5–36.) 2. Adjust the track to move the door to the inside or outside, depending on the alignment with the bottom of the door track. 3. Tighten the five nuts to 7-9 ft•lb (9 to 13 N•m). 4. Check the door action and adjust until it is smooth. 5.3.7.3 Adjusting Lower Door Guide Illustration 5–35 View from the Wheel Well 1. Loosen the six 1/4" screws along the bottom of the side door. (See Illustration 5–37.) CAUTION: Be careful not to chip the paint! Loosen to adjust track. Roller Assembly 2. Adjust the bottom door guide all the way up (into the plastic door track). (See Illustration 5– 38.) 3. If the door scrapes or binds, push the guide down slightly into the track. 4. Cycle the door open and then closed. 5. Tighten the screws along the bottom of the side door. Illustration 5–36 Upper Door Cross Section Pan-head Screw Bottom Door Guide Illustration 5–37 Loosen Screws Canada Post Body Service Manual Plastic Door Track Aluminum Retainer Illustration 5–38 Lower Door Cross Section 69 5.4 Bulkhead Door 5.4.1 Removal 1. Use a #11 (3/16" [5 mm]) drill bit to drill out the rivets securing the lower door track to the door. 2. Drill out the rivets securing the door to the roller assembly. 3. Lift door up and out to remove. 5.4.2 Replacement 1. Reverse the removal procedure. 5.4.3 Latch Adjustment 1. Locate and loosen the two screws on the striker. (See Illustration 5–39.) 2. Position the striker to align with the latch on the bulkhead panel. Illustration 5–39 Bulkhead Door Latch (Cargo Side) 3. Holding the striker in this new position, tighten the screws. 4. If the door still does not align, repeat the procedure. NOTE: You can make the door close tighter with this adjustment. 70 Canada Post Body Service Manual 6.0 Hood 6.1 RIM Hood Surface Repair Use this process if the hood has a hole, gouge, or scratches. NOTE: Depending on the severity, a damaged hood may not be repairable. 1. Purchase a flexible bumper/fender repair kit at an auto supply store. 2. Follow the kit’s surface preparation instructions carefully. 3. Touch up with paint. (See Section 11.5.) Grab Handle Fender Hinges Gas Shock Hood Center Support Spring Grill Support Strut Center Support Grill Bars Reflector Headlight Lower Hood Support Turn Light Side Marker Hood Brace Bumper Hold Down Strap Illustration 6–1 Hood Assembly Canada Post Body Service Manual 71 6.2 Gas Springs 6.3 Hood Removal and Replacement 6.2.1 Removal 6.3.1 Removal 1. Lift the hood and secure it so that it will stay open when the gas springs are removed. 2. Carefully insert a small flathead screwdriver under the clip at the bottom of the gas spring. (See Illustration 6–2.) 3. Lift up slightly on the clip. The spring will slide off the ball stud. NOTE: Do not remove the clip from the spring because it is difficult to reattach. 4. Repeat the same steps for the top of the spring. 6.2.2 Replacement 1. Snap the top of spring onto the ball stud. 2. Repeat for the bottom of the gas spring. 1. Lift the hood and secure it so that it will stay open when the gas springs are removed. 2. Disconnect the hood gas springs. (See Section 6.2.1.) 3. Disconnect the hood wiring (2 places) from the cowl harness. (See Illustration 6–3.) 4. Remove the bolts on the hood hinge working from the center out. Discard all fasteners. (You may have to remove insulation to reach the bolts.) 5. While supporting the hood from both sides, carefully remove the two outside 1/4–20 Torx® screws and remove the hood away from the vehicle. 6.3.2 Replacement 1. Position the hood on the front of the vehicle. 2. Align the hood hinge holes with the holes on the cowl. 3. Insert one Torx® screw with a washer in each outside hinge hole. Do not tighten completely. (See Illustration 6–4.) Hood Wiring Fit screwdriver head under clip to release gas spring from the socket Disconnect Here Lamp Assembly Illustration 6–2 Releasing Gas Spring from Ball Socket 72 Illustration 6–3 Hood Wiring Canada Post Body Service Manual CAUTION: Lifting the hood too high can damage the wiper arms or even break the windshield. Use extreme caution in this process. Insert Torx screw in outside hole on each hinge and check center alignment. Illustration 6–4 Use Torx® Screws to Center the Hood on the Truck Body 4. Using new bolts, place new two-way locknuts and washers on the cowl side of each of bolt and leave loose. 5. Using a 7/16" wrench, hold the locknut while tightening. Snug the bolts but do not tighten completely. 6. Lower the hood gently and check the alignment with the fender guides. (See Illustration 6–6.) Connect headlight wire harnesses. 7. Check the hood to insure that it is centered on the structure. NOTE: If the hood is not centered on the body, loosen the hood hinge bolts and recenter the hood. 8. Lift both sides of the hood straight up simultaneously. 9. Tighten the two outside Torx® screws. Attach gas spring to ball sockets. Illustration 6–5 Connect Electrical Harnesses and Gas Springs Canada Post Body Service Manual 73 10. Tighten the remaining bolts across the hood hinges. Be sure to use new locknuts and bolts. 11. Connect the headlight wire harnesses. (See Illustration 6–5.) 12. Attach the hood gas springs on either side. (See Section 6.2.) 13. Lower the hood again to check for the proper alignment. (See Section 6.4.) 6.4 Hood Adjustment 6.4.1 Fender to Quarter Panel 1. To align the RIM fender to the quarter panel, loosen the two nuts attaching the hood support strut to the hood brace. (See Illustration 6–1.) Illustration 6–1 Support Strut 2. Loosen the nuts attaching the hood support strut to the upper gas spring support. (See Illustration 6–2.) 3. Loosen the nuts attaching the hood bumper to the bumper guide. (See Illustration 6– 3.) 4. Adjust fender to fit and torque all nuts to 5 ft•lb (6.8 N•m). 6.4.2 Hood Stops Illustration 6–2 Upper Gas Strut NOTE: The hood stops set the gap between the quarter panel and fender. (See Illustration 6–4.) 1. To adjust the gap between the quarter panel and fender, loosen the four nuts to the bumper mounts (two each side). (See Illustration 6–5.) CAUTION: Only loosen fasteners enough to allow adjustment. Removing the nut completely or repetitive adjustment will damage the two-way lock nuts and require replacement of both the nut and the bolt. 74 Canada Post Body Service Manual Front to back adjusting bolts Side to side adjusting bolts. Front to back adjusting bolts. Illustration 6–3 Hood Guide Bumper Bracket Adjustments NOTE: The hood stops may be set in place with a set screw. Remove before you continue. (See Illustration 5-6.) 2. Adjust the mounts until the surfaces in the gap between the quarter panel and fender are parallel when the hood is closed. (See Illustration 6–4.) Use the vertical slots to widen the gap by raising the mounts or narrow the gap by lowering the mounts. Adjust side to side. Adjust front to back. 3. Make the rubber bumpers snug against the lower hood support. They should be flush and perpendicular to the extrusion at all points of contact. (See Illustration 6–6.) 4. Torque all nuts to 14–18 ft•lb (19–24.4 N•m). Optional: To secure the location after adjustment, a 1/4-20 x 3/ 4" bolt and nut can be added as a set screw by drilling a new hole behind the adjustment slot. (See Illustration 6–6.) Illustration 6–4 Check Hood Alignment CAUTION: Only loosen fasteners enough to allow adjustment. Removing the nut completely or repetitive adjustment will damage the two-way lock nuts and require replacement of both the nut and the bolt. Canada Post Body Service Manual 75 6.5 Fenders 6.5.1 Removal NOTE: Removing the hood from off of the truck (See Section 6.3) may make replacing the fender easier. 1. Disconnect the hood spring, Section 6.2.1. 2. Remove the two bolts holding the support strut. (See Illustration 6–1.) 3. Remove the Huck fasteners attaching the fender to the center hood section, grill bars, and hinge. Illustration 6–5 Hood Stops 4. Remove the rivets that attach the grill to the fender. 5. Remove the headlight. (See Section 9.2.) 6. Remove the front turn light. (See Section 9.3.) Hood 7. Remove the side marker light. (See Section 9.4.) 8. Remove the wire harness. Mount 9. Remove the bumper bracket. 6.5.2 Replacement 1. Decide the best paint process before assembling the hood. Painting the fender before assembly has its advantages and disadvantages depending on the individual situation. (See Section 6.5.3.) 2. Align the aluminum of the hood center to the plastic seam along the fender. Clamp in place. (See Illustration 6–1.) Set Screw Illustration 6–6 Hood Stop Alignment 3. Using the holes in the aluminum hood center as a template, drill holes into the fender. 4. Position the hood brace to the inside of the hood. Us the holes in the bracket as a template to drill holes in the fender. 76 Canada Post Body Service Manual 5. If a huck fastening system is not available, use (Grade 8) 1/4-20 x 3/4" Phillips-head truss bolts to attach the fender to the aluminum. Use a (Grade 8) locknut. 6. Install the wire harness and side marker light. (See Section 9.4.) 7. Install the front turn light. (See Section 9.3.) 8. Install the headlight. (See Section 9.2.) 9. Attach the support strut with new bolts and locknuts. 6.6 Grill 6.6.1 Removal 1 Using a #11 (or 3/16") drill bit and drill, remove the rivets on the screen (be sure to remove all of the rivet). 2. Remove the grill. 6.5.2 Replacement 1. Position the new grill into place. 2. Attach the replacement grill with 3/16" pop rivets. 10. Attach the bumper bracket with new bolts and locknuts. 11. Attach the upper gas spring support with new bolts and locknuts. 6.5.3 Painting a NEW Fender 1. Using water, a granulated household cleaner (e.g., Spic and Span), and an abrasive pad (e.g., Scotch-Brite™) wash the area to be painted. NOTE: As much as possible avoid getting lubricants, oils, marking pens, grease, and aerosols from an air line on the hood. These materials have a tendency to soak into the substrate of the hood and interfere with paint performance. 2. Rinse the surface thoroughly with water. 3. See Section 11.5 for painting instructions. Canada Post Body Service Manual 77 7.0 Seats and Seat Belts 7.1 Driver’s Pedestal 7.1.1 Removal 1. Remove and discard the four (4) bolts attaching the pedestal to the cabin floor. (See Illustrations 7–1.) 2. Remove the one (1) bolt attaching the seat belt to the pedestal. (See Illustration 7–9.) 3. Pull out the pedestal seat. 7.1.2 Replacement 1. Reverse the removal procedure. 2. Replace fasteners with new Grade 5 or better and torque them to 70 ft•lb (95 N•m). 7.2 Driver’s Seat Illustration 7–1 Four Bolts Attach Seat Pedestal to Floor Base 7.2.1 Removal 1. Remove the four nuts and lock washers attaching the seat to the pedestal. (See Illustration 7–2.) 2. Pull off the seat from the pedestal. 7.2.2 Replacement 1. Reverse the removal procedure. 2. Replace fasteners with Grade 5 or better, and torque them to 12–14 ft•lb (16.5 to 18.5 N•m). Illustration 7–2 Four Nuts and Lock Washers 78 Canada Post Body Service Manual WARNING: Read vendor instructions carefully. Failure to install and inspect can result in injury or death of user. NOTE: Do not remove cardboard spacer until the retractor is mounted. The retractor must be mounted at the proper angle before web will freely extend. Cardboard spacer must be removed after seatbelt is fully installed. Highback Seat D-Loop Buckle Retractor Buckle Latch Plate Pedestal Illustration 7–3 Driver’s Seat Installation Canada Post Body Service Manual 79 7.3 Seat Belt Maintenance 7.3.1 Important Facts Your occupant restraint system has been developed and tested specifically for delivery vehicles. The high usage associated with delivery vehicle application and exposure of this seat belt to severe environmental conditions make it crucial to inspect the three-point seat belt system regularly. The seat belt system must be inspected during every routine maintenance. A seat belt system should be replaced immediately if it shows any problem such as cuts, fraying, extreme, or unusual wear, significant discolorations due to ultraviolet exposure, significant dirt, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor, or hardware. Replace the seat belt with only a belt recommended by Utilimaster. If any part of the seat belt requires replacement, the entire belt must be replaced. An installation guide is attached to every replacement belt. If the seat belt is replaced, all components must be mounted back in the same position as the original components. This will maintain the design integrity of the mounting points for the seat belt assembly. WARNING: Belts must be inspected during every routine maintenance. Failure to properly inspect and maintain the seat belts can cause serious injury or loss of life. The seat belt in a delivery vehicle application has a finite life and must be replaced as needed throughout the life of the vehicle. Whenever a vehicle is involved in an accident, the entire seat belt system must be evaluated for replacement, even if there is no visible wear or damage to the seat belt system. 7.3.2 Maintenance Guidelines The following maintenance guidelines detail how to inspect seat belts. If any of these problem conditions are found, the entire seat belt system must be replaced. Web cut, frayed, or worn at latch area 7.3.2.1 Seat Belt Webbing Examine seat belt webbing in the seat system for cuts, frays, extreme or unusual wear, significant dirt, or extreme faded color due to exposure to ultraviolet rays. (See Illustration 7–4.) Buckle latch plate 7.3.2.2 D-Loop Web Guide The D-Loop Web Guide is an area where there is a significant amount of webbing movement in a delivery vehicle during the use of the seat belt system. If the web is cut or frayed at the D-Loop Web Guide, the entire belt system must be replaced. (See Illustration 7–5.) 80 Illustration 7–4 Latch Plate Wear Canada Post Body Service Manual 7.3.2.3 Retractor System Web cut, frayed, or worn at D-Loop guide. The retractor, the heart of the occupant restraint system, contains a locking mechanism and serves as a storage device for the webbing when not in use. Check the retractor web storage device operation to ensure that it is not locked up. The seat belt webbing must spool out freely and retract properly. (See Illustration 7–8.) 7.3.2.4 Seat Belt Buckle Illustration 7–5 D-Loop Wear Buckle cracked or broken. Check the buckle for proper operation by inserting the latch and listening for an audible click. Verify that the buckle is not damaged and that the plastic casing is not broken or cracked. Examine the seat belt buckle cable strap to determine if there is unusual wear, the cable is damaged, or if the cable is cut or frayed. (See Illustration 7–6.) 7.3.2.5 Buckle Latch Plate Check the buckle latch plate for excessive wear. Make sure that the buckle latch is neither bent nor deformed. It must latch properly into the buckle. (See Illustration 7–4.) 7.3.2.6 Seat Belt Height Adjuster Check the height adjuster for proper operation, making sure that there is no damage. If the height adjuster does not move up and down freely and lock at different height positions, the seat belt must be replaced. (See Illustration 7–7.) Damaged or frayed cable. Illustration 7–6 Buckle Wear Canada Post Body Service Manual 81 WARNING: When a seat belt is replaced, both halves must be replaced. 7.4 Driver’s Seat Belt NOTE: The outboard side refers to the side closest to the door. The inboard side is the side toward the center of the vehicle. 7.4.1 Removal 1. Remove the bolt attaching the D-Loop to the seat belt mount above the seat on the outboard side. (See Illustration 7–7.) 2. Snap open the retractor cover and remove the bolt. Discard the locknut. (See Illustration 7–8.) Illustration 7–7 D-Loop Attached to Seat Belt Hieght Adjuster 3. Remove the bolt holding the seat belt end bracket attached to the outboard side of the seat. See Illustration 7–9.) 4. On the inboard side of the seat, remove the bolt holding the seat belt (buckle) assembly. (See Illustration 7–10.) WARNING: Use the new mounting hardware furnished with the replacement belt. Do not use old hardware when installing replacement seat belts. Illustration 7–8 Retractor Uncovered CAUTION: Do not remove the cardboard spacer until the retractor is mounted and seat belt is fully installed, otherwise the belt will retract and bind. 7.4.2 Replacement 1. Mount the seat belt D-Loop in the existing hole in the seat belt mounting bracket. Torque bolt from 35 to 50 ft•lb (47.5 to 67.5 N•m). (See Illustration 7–7.) 2. Snap open the retractor cover and insert the locating pin at the back of the retractor into the mounting bracket in the bulkhead wall. WARNING: When installed, the D-Loop must rotate freely. The D-Loop must return to the horizontal position when the belt is retracted. 82 Illustration 7–9 Safety Belt End Bracket Canada Post Body Service Manual WARNING: The retractor must be located in the proper position on the bracket for the seat belt web to extract and function properly. 3. Insert the retractor mounting bolt and tighten the bolt to 35–50 ft•lb (47.5 to 67.5 N•m). (See Illustration 7–8.) 4. Snap the retractor cover down into place. 40 to 60 Degrees 5. Mount the safety belt end bracket in the existing hole on the seat pedestal. Torque the bolt from 35 to 50 ft•lb (47.5 to 67.5 N•m). (See Illustration 7–9.) 6. Mount the seat belt (buckle) assembly on Illustration 7–10 Seat Belt Buckle the inboard side of the seat with the release button facing away from the seated driver. Torque bolt from 35 to 50 ft•lb (47.5 to 67.5 N•m). (See Illustration 7–10.) WARNING: The seat belt assembly should be at an angle of approximately 40° to 60° upward off the horizontal. 7.5 Jump Seat 7.5.1 Removal 1. From the cargo area, remove the 1/4–20 bolts attaching the upper seat back to the bulkhead. (See Illustration 7–11.) 2. Remove and discard the 3/8–16 bolts and locknuts attaching the lower jump seat to the bulkhead. 7.5.2 Replacement 1. Align the jump seat with holes on the bulkhead and attach with new 3/8–16 bolts (Grade 5 or better) and two-way locknuts. 2. Torque fasteners to 28–32 ft•lb (38 to 43 N•m). 3. Align the jump seat back with holes on the bulkhead and attach with 1/4–20 screws. 4. Torque fasteners to 8–9 ft•lb (11 to 13 N•m). WARNING: The seat belt assembly should be at an angle of approximately 40° to 60° upward off the horizontal. Canada Post Body Service Manual 83 WARNING: Read vendor instructions carefully. Failure to install and inspect can result in injury or death of user. NOTE: Do not remove cardboard spacer until the retractor is mounted. The retractor must be mounted at the proper angle before web will freely extend. Cardboard spacer must be removed after seatbelt is fully installed. Upper Seat Back Lower Jump Seat Seatbelt Buckle Retractor Illustration 7–11 Jump Seat Installation 84 Canada Post Body Service Manual WARNING: When a seat belt is replaced, both halves must be replaced. 7.6 .Jump Seat Belts The outboard side refers to the side closest to the door (jump seat occupant’s right-hand side). The inboard side is the side toward the center of the vehicle. 7.6.1 Removal 1. Remove the bolt attaching the D-Loop to the bulkhead above the seat on the outboard side. 2. Snap open the retractor cover and remove the nut and bolt. 3. Remove the nut and bolt holding the seat belt bracket to the seat belt mount just below the seat on the outboard side. (See Illustration 7–12.) 4. On the inboard side of the seat, remove the nut and bolt holding the seat belt (buckle) assembly. (See Illustration 7–13.) Illustration 7–12 End Bracket Attached to Seat Belt Mount WARNING: Use the new mounting hardware furnished with the replacement belt. Do not use old hardware when installing replacement safety belts. WARNING: When installed, the D-Loop must rotate freely. The D-Loop must return to the horizontal position when the belt is retracted. 7.6.2 Replacement 1. Remount the seat belt D-Loop using the existing hole in the bulkhead. WARNING: The retractor must be located in the proper position on the bracket for the seat belt web to extract and function properly. 2. Snap open the retractor cover and insert the locating pin at the back of the retractor into the mounting bracket in the bulkhead wall. CAUTION: Do not remove the cardboard spacer until the retractor is mounted and seat belt is fully installed, otherwise the belt will retract and bind. Canada Post Body Service Manual 85 3. Insert the mounting bolt and tighten the nut to 32–50 ft•lb (43 to 67.5 N•m). 4. Snap the retractor cover down into place. 5. Mount the seat belt end bracket to the seat belt mount below the seat on the outboard side. (See Illustration 7–12.) 6. Tighten the nut to 35–50 ft•lb (43 to 67.5 N•m). 7. Mount the seat belt (buckle) assembly on the inboard side of the seat with the release button facing away from the occupant. Torque the bolt from 35 to 50 ft•lb (43 to 67.5 N•m). (See Illustration 7–13.) 40 to 60 Degrees WARNING: The seat belt assembly should be at an angle of approximately 40° to 60° upward off the horizontal. Illustration 7–13 Seat Belt Buckle 86 Canada Post Body Service Manual 8.0 Heating System Defroster Duct Transition Duct Clamp Louvers Control Valve Flexible Heat Duct Hose Controller Air Plenum Inlet Wire Harness Heater Coil Fresh Air Inlet Heater Hose Spacers Left Floor Duct Blower Inlet Duct Heater Plenum Right Floor Duct Resistor Motor Blower Blower Wheel Housing Illustration 8–1 Heating System Canada Post Body Service Manual 87 8.1 Blower Motor 8.2 Heater Resistor 8.1.1 Removal 8.2.1 Removal 1. Disconnect the battery negative (black) cable. 1. Disconnect the battery negative (black) cable. 2. Remove the electrical connections from the blower motor. (See Illustration 8–2.) 2. Remove the resistor cover plate. 3. Remove the blower motor vent tube. 4. Remove the attaching screws. 5. Remove the blower motor assembly from the housing. 6. Remove the blower wheel retaining nut. NOTE: Nut threads are standard righthand threads. 3. Remove the electrical connections from the resistor assembly. 4. Remove the resistor assembly. (See Illustration 8–1.) 8.2.2 Replacement 1. Position the new resistor. 2. Attach with screws, and torque from 12 to 15 in•lb (16.5 to 20 N•m). 7. Remove the blower wheel from the blower motor. 3. Attach the electrical connections. 8. Remove the blower wheel stop (clip) from the motor shaft. 5. Connect the battery negative (black) cable. 8.1.2 Replacement 1. Install the blower wheel stop on the new motor. 4. Install the resistor cover plate. Disconnect electrical connector. 2. Install the blower wheel. 3. Install the retaining nut and torque it to 25 in•lb (34 N•m). 4. Position the blower assembly in the housing. 5. Attach with screws, and torque them to 12 to 15 in•lb (16.5 to 20 N•m). Disconnect vent tube. 6. Attach the electrical connector. 7. Reattach the blower motor vent tube. 8. Connect the battery negative (black) cable and check the blower motor for proper operation. 88 Illustration 8–2 Disconnecting Blower Motor Canada Post Body Service Manual 9.0 Lights and Wiring 9.1 Wiring See the Canada Post Body Wiring Manual (P/N 03102644–WY01EN) for general wiring schematics. 9.2 Headlight Replacement and Adjustment 9.2.1 Removal 1. Turn off the ignition and all lights. 2. Open the hood. 3. Disconnect the electrical harness from the back of the headlight unit. (See Illustration 9–1.) Remove Remove screws.screws. 4. With a Phillips-head screwdriver and a wrench, remove the four (4) retaining screws and nuts from the retaining ring. (See Illustration 9–2.) Disconnect electrical harness. 5. Remove the used headlight unit from the retaining ring. Disconnect electrical harness. 9.2.2 Replacement 1. Place the new headlight unit in the retaining ring. 2. Secure the four (4) retaining screws, and torque the nuts from 12 to 18 in•lb (16.5 to 24 N•m). Illustration 9–1 Disconnecting the Headlight Unit 3. Reconnect the electrical harness at the back of the headlight unit. 4. Close and securely latch the hood. Illustration 9–2 Headlight Retaining Screws Canada Post Body Service Manual 89 9.2.3 Adjustment 1. Remove any load the vehicle is carrying. 2. The vehicle should have approximately a half tank of fuel. 3. Check that the tires are properly inflated to 110 PSI (0.758 mPa). 4. Clean the headlights if they are dirty. 5. Park the vehicle on a level surface. 6. Use a headlight-aiming tool to gauge correct alignment of the headlights. Follow the manufacturer’s instructions for the device as needed. (If no headlight-aiming tool is available, perform steps 8 through 11 as a temporary solution until a tool can be obtained.) 7. Turn the adjuster screws to move the headlights up or down and left or right as necessary. (See Illustration 9–3.) 8. If no headlight-aiming tool is available, park the vehicle on a level surface near a wall, and mark the point opposite the center of each headlight. 9. Draw or tape a cross through each mark. Illustration 9–3 Headlight Adjusting Screws 11. Adjust the low-beam headlights so that the majority of the beam is below the horizontal target marks and centered on the vertical target marks. (See Illustrations 9–4 and 9–5.) NOTE: Steps 8 through 11 should be used only until a properly calibrated headlightaiming tool can be obtained. 10. Park the vehicle a distance (measured from the headlight) of 25 feet (7.62 meters) from the wall. Illustration 9–4 Improperly Aligned Pattern 90 Illustration 9–5 Properly Aligned Pattern Canada Post Body Service Manual 9.3 Forward Turn Signal Light 1. Turn off the ignition and all lights. 2. Using a #11 or 3/16" (5 mm) drill bit, drill off the heads of the two (2) rivets holding the light unit to the hood. 3. Open the hood. 4. Disconnect the electrical harness at the back of the turn signal light unit. Illustration 9–6 Forward Turn Signal 5. Position the new unit on the outside of the hood and attach the electrical harness at the back of the unit. 6. Close the hood and pop rivet the turn signal light in place. 9.4 Front Side Marker Light 1. Turn off the ignition and all lights. 2. Lightly spray the outer grommet and marker light surface with soapy water to ease the removal of the marker light unit. 3. Slip a flathead screwdriver between the light and the inner lip of the grommet to pry the marker light up so that it can be pulled out of the grommet. (See Illustration 9–7.) 4. Disconnect the old light unit from the electrical harness. 5. Check the rear (inside the hood) of the grommet before installing the new light and adjust the grommet, if necessary. CAUTION: The slit on the rear of the grommet must be pointed down when the hood is closed to allow water to drain. 6. Lightly spray the grommet again with soapy water. 7. Plug the new light unit into the harness. 8. Replace the light unit by pushing it through the front of the grommet (on the outside). CAUTION: The metal bars inside the light unit must be parallel with the ground. Illustration 9–7 Front Side Marker Light Canada Post Body Service Manual 91 9.5 Clearance and Identifcation Lights 1. Turn off the ignition and all lights. 2. Use a medium-sized Phillips screwdriver to remove the two outside screws attaching the light unit to the vehicle. NOTE: The light unit is a sealed unit and must be replaced as a unit. (See Illustrations 9–8 and 9–9.) 3. Disconnect the light unit from the electrical harness. Illustration 9–8 Front Clearance Light 4. Connect the new light unit and attach it to the vehicle using two Phillips-head screws. 9.6 Taillights (Brake, Back-Up, Hazard, and Turn) 1. Turn off the ignition and all lights. 2. Using a #11 or 3/16" [5 mm] drill bit, drill off the heads of the three (3) rivets holding the light unit to the rear of the vehicle. 3. Disconnect the electrical harness at the back of the unit. 5. Attach the electrical harness to the back of the new unit. Illustration 9–9 Rear Clearance Light 6. Align the predrilled holes of the new light unit and pop rivet the unit in place. Illustration 9–10 Taillights 92 Canada Post Body Service Manual 9.7 License Plate Light 1. Turn off the ignition and all lights. 2. Pinch the lens from the sides just enough to pop the lens off the light fixture. (See Illustration 9–11.) 3. With a half turn, remove the old bulb. 4. Replace the bulb. 5. Snap the lens back into place. 9.8 Dome (Cab) Light 1. Turn off the ignition and all lights. Illustration 9–11 License Plate Light 2. Remove the three Phillips-head screws holding the dome light lens and remove the lens. (See Illustration 9–12.) 3. Remove the bulb with a half turn. 4. Place the new bulb in the light fixture. 5. Use three Phillips-head screws to reattach the unit. 9.9 Cargo Lights 1. Turn off the ignition and all lights. 2. Remove the three (3) screws holding the unit to the bulkhead. (See Illustration 9–13.) Illustration 9–12 Cab (Dome) Light 4. Disconnect the old light from the electrical harness at the back of the unit. 5. Plug the electrical harness into the back of the new light unit and then align the unit with the screw holes on the bulkhead. 6. Use three Phillips-head screws to reattach the unit. Illustration 9–13 Cargo/Bulkhead Light Canada Post Body Service Manual 93 9.10 Dash Switch (Cargo, Dome) 1. Disconnect the negative (black) terminal of the battery. 2. Remove the instrument panel. (See Section 10.6.1.) Switch Body Actuator Actuator snaps on switch body. Detach harness 3. Detach the electrical harness from the back of the switch body. 4. Squeeze the top and bottom of the switch body to remove it from the panel. 5. Pop off the actuator. Squeeze tabs to release switch body from bracket. Illustration 9–14 Switch Components 6. Snap the new actuator onto the new switch body, and then reverse the above procedure. 7. Reconnect the battery. 8. Test the function of the switch. 94 Canada Post Body Service Manual 10.0 Miscellaneous Repairs 10.1 Grab Handle CAUTION: Use new stainless steel fasteners for all grab handles. NOTE: This vehicle has a grab handle on the bulkhead door and one on the hood. They are all removed and replaced in the same manner. 10.1.1 Removal 1. While holding the handle, remove the four (4) stainless steel Phillips-head fasteners from the handle. 2. Handle should release into your hand. (See Illustration 10–1.) 10.1.2 Replacement Illustration 10–1 Grab Handles 1. Position the new handle in place. 2. Insert four (4) stainless steel fasteners and torque them 2 to 3 ft•lb (2.7 to 4 N•m). Canada Post Body Service Manual 95 10.2 Roof Vent 10.2.1 Removal 1. From the exterior of the vehicle, remove and discard the four (4) stainless steel 8 x 1" Phillips pan-head screws that attach the non-powered roof vent to the backing plate. (See Illustration 10–2.) 2. Gently cut the sealant around the circumference of the vent before removing the vent from the roof. 3. Remove any excess sealant from vent mounting area. Illustration 10–2 Roof Vent (Exterior View) 4. Clean with a lacquer-based solvent. 5. From the cargo area, remove four (4) 8 x 1/2" pan-head screws to replace the garnish vent (if necessary). (See Illustration 10–3.) 10.2.2 Replacement 1. On the outside of the vehicle, apply gray polyurethane sealant around the circumference of the roof vent flange. 2. Align the vent with the holes in the roof and the vent backing plate. 3. Using stainless steel 8 x 1" Phillips pan-head screws, reattach the vent to the roof. (See Illustration 10–2.) Illustration 10–3 Roof Vent (Interior View) 4. From the exterior, apply a bead of sealant to the joint between the vent and the roof. 5. From the cargo area, reattach the garnish vent to the vent plate using four (4) 8 x 1/2" pan-head screws. (See Illustration 10–3.) 96 Canada Post Body Service Manual 10.3 Sun Visor 10.3.1 Removal NOTE: The sun visor arms and pad are replaced as a unit. (See Illustration 10–4.) Adjust the arm width to match the existing mounting holes. 1. Using a wrench, hold the two-way locknut on the top of the shelf. 2. While holding the sun visor, remove the four (4) bolts. (See Illustration 10–5.) 10.3.2 Replacement 1. Position the new sun visor assembly on the shelf and attach with the four (4) new 10– 24 x 1" flathead Phillips-head bolts and two-way locknuts. Illustration 10–4 Sun Visor Unit 2. Torque the locknuts 28 to 42 in•lb (3.2 to 4.7 N•m). Illustration 10–5 Each Arm has Two Fasteners Canada Post Body Service Manual 97 10.4 Mirrors 10.4.1 Removal NOTE: All mirror heads can be replaced by removing a single hex-head nut and star washer. NOTE: The heated mirror cable enters the cab through a heat-shrink grommet and the cable is hard-wired into the vehicle’s electrical system. (See Illustrations 10–6 and 10–7.) 1. Disconnect the battery negative (black) cable. 2. Inside the cab, cut the heated mirror cable at a point where rewiring the new cable will not be a problem. 3. Remove the grommet. 4. Using a 1/2" socket wrench, remove the mirror loop from the mirror mounting brackets. (See Illustration 10–8.) Illustration 10–6 Side Mirror NOTE: An alternative would be to remove the mirror loop and brackets as a unit by removing the four (4) Phillips pan-head screws and locknuts (two each on the upper and the lower brackets). 10.4.2 Replacement 1. Using a 1/2" socket wrench, tighten the upper mirror loop 5/16–18 x 2" hex-head bolt and locknut to crush the spring to a third of its overall length. 2. The lower 5/16–18 x 1" hex-head bolt and locknut should be tightened from 100 to 150 in•lb (11.5 to 16.5 N•m.). Illustration 10–7 Heated Mirror Cable Enters Cab Through Heat-shrink Grommet 3. If mirror mount brackets were removed, use two (2) new stainless steel Phillips pan-head screws and new locknuts on each of the brackets. (See Illustration 10–8.) NOTE: Do not reuse two-way locknuts—use new ones. Use stainless steel fasteners on the exterior to mount mirrors. 4. Thread the mirror cable through the grommet and heat-shrink the grommet. 98 Illustration 10–8 Use Stainless Steel Fasteners on the Exterior Canada Post Body Service Manual Gently insert pointed tool through drain top (from inside cargo area) Or squeeze bottom “lip” edges to release accumulation (from underneath vehicle). Illustration 10–9 “Kazoo” Drain Clean the “Kazoo” drains in the rear cargo floor corners. 5. Splice the new mirror cable back into the electrical harness. 6. Reconnect the battery negative (black) cable. NOTE: Adjust the mirrors as little as possible for the first 72 hours after installation. 10.5 Rear Kazoo (Duck–Bill) Drain Valves 10.5.1 Cleaning Clean the rubber “Kazoo” drain valves in the rear cargo floor corner periodically to ensure that the drain is not blocked by debris or dirt and is able to drain properly. (See Illustration 10–9.) • From the interior of the vehicle, use a small pointed tool, such as a pen or small screwdriver, to gently poke down through the drain. • Or, from underneath the vehicle, you can squeeze the wide section on the bottom to open the “lips” and release any accumulation that did not drain normally. 10.5.2 Removal 1. From underneath the vehicle, drill out two (2) pop rivets. (See Illustration 10– 10.) 2. Remove drain valve assembly. 10.5.3 Replacement 1. Position new drain valve assembly. 2. Pop rivet into place. Canada Post Body Service Manual Illustration 10–10 “Kazoo” Drain Installation 99 CAUTION: Disconnect the negative terminal on the battery before working underneath the dash. 10.6 Dash Panel Assembly (Ford) 10.6.1 Removal 1. Disconnect the negative (black) terminal on the battery. 2. Remove and set aside the five instrument panel screws (three on the top and two on the bottom) that hold the instrument panel face plate to the dash. (See Illustration 10–11.) Illustration 10–11 Instrument Panel Screws 3. Disconnect the wire harnesses behind the instrument panel and set the panel aside for later reassembly. 4. Remove the four screws holding the heater control module to the dash. (See Illustration 10–12.) 5. Disconnect the cables at the back of the heater control module so the module can be removed from the dash. Set aside the module with the screws for later reassembly. 6. Remove the Phillips-head screw on the left side of the dash. (See Illustration 10–13.) Illustration 10–12 Disconnect Heater Control Module Illustration 10–13 Location of Screw on the Left Side of the Dash 100 Canada Post Body Service Manual Plastic Drive Rivet Illustration 10–14 Location of Screws and Bolt on the Right Side of the Dash Illustration 10–15 Location of Screws Above the Steering Column 7. Remove the four Phillips-head screws holding the right-hand cable cover. (See Illustration 10–14.) 8. Remove the two Phillips-head screws above the steering column and the three Phillips-head screws in the lower right corner of the dash. (See Illustrations 10–15 and 10–16.) 9. Remove the plastic drive rivet in the upper right corner of the dash by prying between the head and the base with a flat blade knife or screw driver until the rivet pops up. (See Illustration 10–14.) 10. Lift the dash up by the base and reach under the dash to disconnect the two air ventilation hoses from the plenum. Illustration 10–16 Location of Screws Below the Steering Column 11. Disconnect the headlight wire connectors (on the left side) from the back of the dash panel. 12. Disconnect the interior lights and defroster switches, identify and tag the connectors at the back of the switch bodies so that they can be reconnected in the same order. (See Illustration 9–14.) 13. Remove the wires from the back of the switch bodies. 14. Remove the dash panel. Canada Post Body Service Manual 101 10.6.2 Replacement 1. With the ventilation hoses still connected to the dash, place the dash over the area behind the steering wheel and reach under the dash to reconnect the ventilation hoses to the plenum. 2. Pull the ends of the heater control cables through the control module port. 3. Attached the color coded cables to the control module and secure with retaining rings. (See Illustration 10– 17.) 4. Reattach the module to the dash. 5. Reattach the wire connectors to the cruise control switches and the headlight, cargo, and dome light switches. Illustration 10–17 Connect Heater Cables 6. Reconnect the wires and controls at the back of the wiper/washer control module and reattach the module to the dash. 7. Reattach the wire harnesses to the instrument panel and mount the panel back on the dash. 8. Make sure all wires are safely tucked back under the dash. CAUTION: In the following steps, take care to not strip the self-tapping screws when remounting the dash. 9. Use six (6) #8 self-tapping screws–one (1) in the upper left corner of the dash, two (2) above the steering column and the remaining three (3) below the steering column–to reattach the dash panel. (See Illustrations 10–13, 10–15 and 10–16.) 10. Use four (4) #8 self-tapping screws to remount the cable cover. (See Illustration 10–14.) 11. Press a plastic drive rivet into the upper right hand corner of the dash. (See Illustration 10–14.) 12. Reconnect the negative (black) terminal on the battery. 102 Canada Post Body Service Manual 11.0 Body Repairs CAUTION: Removal of roof could result in roof leaks. If a vehicle requires major roof or structural repair, check with Utilimaster for recommendation on returning the vehicle to Utilimaster or repairing damage at a body shop. Roof Panel Roof Vent Corner Casting Side Cap (Front) End Rail End Cap Roof Bow Corner Gusset Vent Backers Roof Rail Roof Liner Vent Garnish Insulation Dome Light End Rail Illustration 11–1 Roof Assembly Canada Post Body Service Manual 103 11.1 Roof Assembly 11.1.1 Rear Corner Castings 11.1.1.1 Removal 1. Remove the rivets on the roof’s side and end caps (not the rails) using a #11 (or 3/16" [5 mm]) drill bit and drill. 2. Using a utility knife, cut the sealant around the casting. Pull off the casting. 11.1.1.2 Replacement 1. Scrape off the old sealant and clean the bonding surface with a lacquer-based solvent. NOTE: For the new casting, drill new holes using the old casting as a model (if possible) or mark hole locations from test mounting the casting on the frame. 2. Apply polyurethane sealant along the bonding surface where the casting will mate with the frame. 3. While holding the corner cap in place, rivet the side and end caps using the same rivet holes. 4. Apply a bead of sealant where the cap attaches to the roof. 5. Seal the perimeter of the corner castings. 6. After an eight–hour waiting period, water test the roof. With all doors and windows closed tightly, spray the roof and the top of the side structures near the affected area with water. Check for leaks. (Reseal and retest if any leaks appear.) 104 Canada Post Body Service Manual 11.1.2 Exterior Roof Panel NOTE: The entire roof panel is translucent sheathing. Utilimaster recommends the use of a patch kit such as Kemlite® SunPatch™ (P/N 01900680) where possible. 11.1.2.1 Removal 1. Using a #11 (or 3/16" [5 mm]) drill bit, remove the rivets on the side and end caps (not the rails). Rivet Location Side Cap Roof Crossmember Front View of Sidewall to Roof Section NOTE: Be sure to remove all of the rivet during these steps. 2. Remove the corner castings. (See Section 11.1.1) 3. Remove the side caps. (See Illustration 11– 2). 4. Remove all the rivets securing the roof panel to the side and end rails. 5. Remove the translucent outer fiberglass panel (some prying may be required to break loose the panel from the roof bows). NOTE: Use of a heat gun will help break the adhesive bond holding the translucent panel to the roof bows and rails. 11.1.2.2 Replacement 1. Scrape the rails, caps, and roof bows to remove the old tape and sealant. 2. Clean with a lacquer-based cleaner and allow to dry. CAUTION: For Steps 3 and 4, do not remove the tape paper until the panel is in the proper position. Once the tape sticks to a surface you will not be able to reposition it without starting over and possibly damaging the new Kemlite. 3. Apply the half-inch-wide (13 mm) adhesive tape (P/N 12605933) on all the roof bows. Canada Post Body Service Manual Illustration 11–2 Roof Cross Section 4. Apply the one-inch-wide (25.4 mm) adhesive tape (P/N 12605927) around the roof perimeter on the side extrusion rails and the front and rear end rails. 5. Peel off just a few centimeters of the tape paper at each tape end of the roof perimeter. 6. Peel off just a few centimeters of the tape paper at each end of the roof bows. 7. Lay down the replacement translucent panel. NOTE: As you are lowering the panel, make sure you can reach (from the interior or the exterior) the peeled-off paper on every tape strip. 8. Carefully pull out all the remaining tape paper. 9. Apply pressure around the perimeter (by hand or preferably with a roller) to firmly adhere the tape to the roof. 10. While holding the corner caps in place, rivet the side and end caps using the same rivet holes. 11. Apply a bead of sealant where the cap attaches to the roof. 105 12. Seal the corner rear castings. 13. After an eight-hour waiting period, watertest the roof. With all doors and windows closed tightly, spray the roof and the top of the side structures with water. Check for leaks. (Reseal and retest if any leaks appear.) 11.1.2.3 Repairing the Translucent Sheathing NOTE: Quick and easy fiberglass repair kits are now available for permanently repairing small tears and punctures. These kits such as Kemlite® SunPatch™ repair kit (P/N 01900680) work in a wide range of temperatures and do not require mixing of resins. (See also the Utilimaster Quick Reference Parts Guide available on www.utilimaster.com.) NOTE: Read all instructions prior to WARNING: Use rubber gloves and any appropriate breathing apparatus as recommended by the manufacturer of the kit. starting. 1. Identify the damaged area. 2. Using 60 grit sandpaper, sand an area equal to the size of the patch. The (typical) patch is 30 x 30 cm. Sand until the embossment is no longer visible and the area has a uniform dull appearance. Remove the sanding dust from the patch area with a dry cloth or shop air. 3. On the back side of the damaged area, apply masking tape or packing tape to seal the repair area. This prevents air from entering the patch from the back side. NOTE: Do not open the pouch until you are ready to use it. The material begins to cure as soon as it is exposed to sunlight. 5. Remove the smooth film from the back side of the patch. 6. Lay the smooth side of the patch over the abraded area on the exterior side of the roof so the embossed side of the patch is facing up. NOTE: Be sure that the abraded area is dry. Do not perform the repair if it is raining. Excessive moisture present during the application and curing of the patch hinders its performance. 7. Use a squeegee to work the resin on the embossed side of the patch from the center to the edges. Continue this until a small amount of resin is squeezed out around the perimeter of the patch. NOTE: The patch cures in 10 to 20 minutes after the patch has been exposed to sunlight. 8. Check the patch to see if it is cured. It should be hard to the touch. Resin that is not covered by the film feels tacky, but if the patch feels hard it is cured. 9. Remove the embossed film and the tape from the bottom side of the panel. The repair is complete. NOTE: Expose the resin side of the foil pouch to sunlight until cured before disposal. 4. Take the repair bag and open it by cutting the edges of the foil pouch. 106 Canada Post Body Service Manual Clearance Light Identification Lights Trim Door Track Roof Cap Glass Header Center Post Seal Trim Glass “A” Post Cowl Left Hand Fender Right Hand Fender Seal Quarter Post Inner Fenders Casting Leg Mirrors Gasket Quarter Panel Hood Guide Illustration 11–3 Windshield and Quarter Panel Canada Post Body Service Manual 107 WARNING: A properly installed A-post and Center Post is critical to the structural integrity of the vehicle. Utilimaster recommends that professional body shop replace the A-Post or Center Post. The service technician should read this entire procedures before working on the vehicle. 11.2 A-post NOTE: If replacing both A-posts, replace the A-posts one at a time so that one provides support to the roof while the other is replaced. 11.2.1 Removal 1. Remove the hood. (See Section 6.3.) 2. Remove the windshield and quarterwindow glass. (See Section 3.1.) 3. Remove the side mirrors with brackets. (See Section 10.4.) 4. Brace the header to prevent the roof from sagging. 5. Using a #11 (or 3/16" [5 mm]) drill bit and drill, remove the rivets attaching the windshield A-post. 6. Remove the two outside (top and bottom) rivets on the cowl casting. 7. Pull the A-post out away from the quarter panel and down. 11.2.2 Replacement 1. Use existing holes as a template for drilling holes in the new A-post. 2. Apply urethane sealant to the top of the A-post. 3. Push the new A-post up and into the quarter panel. Slide the post up until it aligns with existing holes. 4. Replace the two outside (top and bottom) rivets on the windshield cowl. 5. Rivet the A-post into place using the existing holes. 108 6. Apply urethane sealant along the interior and outer perimeters of the A-post interfaces. Wipe off all excess sealant with a toluene solvent. 7. Attach the side mirrors and bracket. (See Section 10.4.) 8. Replace the windshield and quarterwindow glass. (See Section 3.1.) 9. Attach the hood. (See Section 6.1.) 11.3 Center Post 11.3.1 Removal 1. Remove the windshield. (See Section 3.1.) 2. Remove the dash. (See Section 10.6.) 2. Remove the transition (defrost) duct by removing the screws. 3. Brace the header to prevent the roof from sagging. 4. From the exterior using a #11 (3/16" [5 mm]) drill bit and drill, remove the four (4) buck rivets above the drip rail that hold the top center post bracket and the two (2) rivets just below the windshield that hold the bottom center post bracket. 5. From the interior, pull out the support. 11.3.2 Replacement 1. Use existing holes as a template for drilling holes in the new support. 2. From the interior, position the new support and clamp in place. 3. From the exterior, using existing holes, rivet the support at the top and the bottom. Canada Post Body Service Manual 4. Remove the clamps. 5. Attach the air defrost ducts. 6. Replace the windshield glass. (See Section 3.1.) 11.4 Quarter Panel 11.4.1 Removal 1. Remove the screws from the bottom of the mirror brackets. (See Section 10.4.) 2. Lift the hood and securely prop the hood up. 3. On the hood gas spring bracket, locate and remove the 1/4–20 bolts from the quarter panel. 4. Remove the hood guide. (See Illustration 11–4.) 5. Remove the panel rivets using a #11 (or 3/16" [5 mm]) drill bit and drill. (Be sure to remove all of the rivets). 6. Using a utility knife, break the seal on the door pillar and along the interface of the panel and the panel frame. Illustration 11–4 Quarter Panel 7. Slide out the panel. 8. Scrape off the old sealant. 11.4.2 Replacement 1. Apply sealant to quarter post, casting, and all support structures. 2. Slide in the panel. 3. Seal the door pillar with a bead of sealant. 4. Rivet the panel to the frame. 5. Seal the interface of the panel and the panel frame. 6. Reattach the hood gas spring bracket. 7. Reattach the hood guide. 8. Reattach the mirror bracket. (See Section 10.4.) Canada Post Body Service Manual 109 CAUTION: Utilimaster recommends that professional body shop do all paint repairs. WARNING: Read entire procedure before starting to work. WARNING: Adequate ventilation is required when working in a confined area with paint and paint-related chemicals. 11.5 Paint 11.5.1 Surface Preparation NOTE: When painting the hood, see also Section 6.1.2. 1. If necessary, follow the procedure in Section 11.6 to remove any decals from the affected area. Illustration 11–5 Use Dupont 3900S and 3901S Cleaners 2. Use a clean rag soaked in Dupont Cleaner 3900S to clean the repair area and the area surrounding the repair. Using a second clean dry rag, wipe off the 3900S cleaner before it evaporates. If the 3900S dries before it is removed, re-wet and wipe dry. (See Illustration 11–5.) CAUTION: Make sure the area cleaned is bigger than the spray area. 3. Sand the defective area with 320 grit sand paper. (See Illustration 11–6.) NOTE: If necessary, use a finer (600 grit) sandpaper to smooth the blend area surrounding the repair area. Illustration 11–6 Sand Area to be Prepared 4. Repeat cleaning with a clean rag soaked in Dupont 3901S Cleaner to remove sanding dust. (See Step 2.) 5. Mask all fixtures (lights, grill, bumper, etc.) to protect from overspray. (See Illustration 11–7.) CAUTION: Use masking tape and a paper that cannot be penetrated by paint. Illustration 11–7 Protect with Masking Tape and Oil Paper 110 Canada Post Body Service Manual 6. Wipe a wide area with the tack cloth to make sure all areas to be sprayed are clean of dust and debris. (See Illustration 11–8.) 7. If the base or substrate is exposed by sanding, apply Dupont 2510S Primer and 2505S Activator. Illustration 11–8 Use Tack Cloth for Final Wipe 11.5.2 Paint Preparation 1. Using a graduated (9 ounce) measuring cup, pour three ounces paint (Dupont® Imron 5000) to one ounce activator (Dupont 193S). (See Illustrations 11–9 and 11–10.) 2. Add 1/8th ounce of accelerator (Dupont 8989S gallon can) to the paint mixture. (See Illustration 11–11.) 3. Using a paint stick, stir paint mixture thoroughly. (See Illustration 11–12.) Illustration 11–9 Three Ounces of Paint 4. Place the paint strainer in the touch-up gun cup and pour the paint through the strainer. (See Illustration 11–13.) CAUTION: Mix paint thoroughly to ensure proper application and paint performance. Illustration 11–10 One Ounce of Activator Illustration 11–11 Add Accelerator Canada Post Body Service Manual Illustration 11–12 Stir Well 111 NOTE: A drop or two of Dupont 359S Paint Additive may be added if there is a problem with “fish eyes” or other contaminate-related imperfections. 5. Reassemble the touch-up gun. 6. Check the blender gun to make sure it has sufficient blender (Dupont 3401S). CAUTION: Utilimaster recommends that professional body shop do all paint repairs. The service technician should read this entire procedures before working on the vehicle. WARNING: Adequate ventilation is required when working in a confined area with paint and paintrelated chemicals. CAUTION: Clear nozzle before spraying. 11.5.3 Touch–up 1. Using the cup gun with Dupont® 222S Adhesion Promoter, do a test spray directed away from the vehicle to make sure the gun nozzle is clear. 2. Spray Dupont 222S Adhesion Promoter across the area to be repaired and extend to the area surrounding the repair to assure adequate adhesion of the new to old paint. 3. Air dry for 1 to 2 minutes. 4. Using the touch-up gun containing Dupont Imron 5000 Paint, do a test spray directed away from the vehicle to make sure the touch-up gun nozzle is clear. Illustration 11–13 Use a Paint Strainer 5. Apply the first coat of paint. (See Illustration 11–14.) 6. Air dry for 1 to 2 minutes. 7. Using the blender gun with Dupont 3401S Blender, do a test spray directed away from the vehicle to make sure the blender nozzle is clear. 8. Apply a first coat of blender. (See Illustration 11–15.) 112 Illustration 11–14 Apply Paint Canada Post Body Service Manual 9. Air dry for 1 to 2 minutes. 10. Apply a second coat of paint, covering an area just beyond the first coat of color. 11. Air dry for 1 to 2 minutes. 12. Apply the final coat of blender, extending just beyond the previous spray patterns. 13. Air dry 3 to 4 hours before removing masking materials. (See Illustration 11– 16.) 14. If the repair is not glossy enough after drying, use buffing compound and buff to achieve the desired appearance. Illustration 11–15 Apply Blender 11.6 Decals 11.6.1 Decal Removal NOTE: If decals were damaged during repair or need to be removed, remove any decals from the affected area as follows: 1. Use a heat gun to soften the adhesive under the decal. 2. With a razor knife, carefully peel the edge back. Illustration 11–16 Air Dry 3 to 4 Hours 3. Continue to heat evenly while manually pulling the decal off. 11.6.2 Decal Installation NOTE: If decals were removed, apply replacement decals. 1. After painting is completed, wait 24 hours for nonreflective decals or 72 hours for reflective decals before applying decals over the repaired paint. 2. Clean the surface with Dupont 2319S Cleaner. 3. Align the decal into position. 4. Smooth the decal from the center to the edges. 5. Squeegee the edges to ensure a proper seal. Canada Post Body Service Manual 113 WARNING: Securely brace bumper from underneath to prevent accident or injury. 11.7 Rear Bumper 11.7.1 Removal WARNING: Securely brace bumper from underneath to prevent accident or injury. 1. On each side, remove the four 1/2–13 x 1-1/2" bolts, washers, and locknuts holding the bumper to the bumper extensions. (See Illustrations 11–18 and 11–19.) Illustration 11–18 Rear Bumper 11.7.2 Replacement WARNING: Use all new bolts and two-way Grade 5 locknuts. Do not reuse locknuts or bolts when replacing bumpers. 1. Position the bumper on top of bumper extensions and align the bumper with the bumper mounting plate. 2. On each side, install four 1/2–13 x 1-1/2" bolts with the bolt heads on the side of the bracket toward the front of the vehicle, and the nuts and washers to the rear of the vehicle. (See Illustration 11–19.) Illustration 11–19 Bumper Mounting Bolts 3. Torque the nuts 75 to 95 ft•lb (101.7 to 128.8 N•m). 114 Canada Post Body Service Manual Index F Fasteners 18 Fender 72, 76 G A A-post (windshield) 108 Actuator, switch 94 Address 3, 10, 11 B Back-up light 92 Belts. See Seat: Belts Blower motor 88 Body mounting bolts 17, 22 Bolts with thread adhesive 22 BOM® 20 Buck rivet 19 Bulkhead door. See Doors Bumper 8, 15, 22, 114 C Cautions 13 Center post (windshield) 108 Certification Label 9 Checklist 14 Coolant 15 Counterbalance 52, 54 Customer service 10 D D-Ring 82, 85 Dash assembly 100 Decals 113 Doors 15 Bulkhead 70 Rear roll-up 52 Side sliding 62 Drain valves (Kazoo). See Kazoo drain E Emergency repairs 13 Canada Post Body Service Manual Gas (hood) springs 72 Grab handle 95 Grill 77 H Handle, grab 95 Heater system 15, 87 Hood Adjustment 74 Fenders 76 Gas springs 72 Grill 77 Inspection 15 Repair 71 Replacement 72 I Inspection 14 K Kazoo drain 99 Keys 51 L Lighting 14 Lights Back-up 92 Brake 92 Cab 93 Cargo 93 Clearance 92 Dome 93 Hazard 92 Headlight 89 Identification 92 License plate 93 Side marker 91 Taillights 92 Turn signal 91, 92 115 M Maintenance 14, 80 Mirrors 17, 98 Monobolt 19 N Notes 13 Notices 3 Nutsert 21 O Online information 3, 10, 12 P Switch Actuator 94 Dash 94 T Tape Double-faced adhesive 22 Vinyl barrier 21 Thread adhesive 22 Tools 18 Torque seal 22 Torque values 25 Towing 13 Trim Molding 33 Paint 77, 110 Parts, ordering 10 Pop rivet 19 Pull strap 8, 60 U Q Vent, roof 96 VIN 9 Visor 97 Quarter panel 106, 109 Quick Reference Parts Guide 106 R Rear threshold drain 17, 99 Reflective tape 17 Revision 3 RIM hood 71 Rivets 19 Roll-up door 52 Roof 104 Roof, vent 96 S Safety Belt. See Seat: Belts Safety warnings 13 Sealant 27 Seals 27, 28, 34, 60, 106 Seat Belts 14, 22, 80, 82, 85 Driver 22, 78 Inspection 14 Jump 83 Serial number 9 Sliding door. See Doors Sun visor 97 116 Utilimaster body serial number 9 V W Warnings 13 Warranty 11 Web site 3, 10, 12, 106 Windows Center post 108 Lower side door 36 Quarter windows 28 Regulator 38 Replacement glass 29 Roll-up side door 37 Sliding side door 34 Tool kit 28 Windshield 108 Wiper/washer system 15, 40, 46 Pivot and link assembly 45 Pivot assembly 48 Troubleshooting 41 Wiper arm 47 Wiper blade 46 Wiper motor 44 Canada Post Body Service Manual Notes Canada Post Body Service Manual 117 118 Canada Post Body Service Manual