Textron Stampede 900 2017 Repair And Service Manual

Technician’s Repair and Service Manual

2018

668061-B

SAFETY

For any questions on material contained in this manual, contact
an authorized representative for clarification.

Read and understand all labels located on the vehicle. Always
replace any damaged or missing labels.

The STAMPEDE 900 is an off road vehicle. Familiarize yourself
with all laws and regulations concerning the operation of this vehi­cle in your area.

The following symbols appear throughout this manual and on your
vehicle. Your safety is involved when these symbols are used.
Become familiar with their meanings before reading the manual.

DANGER indicates a hazardous situation
that, if not avoided, will result in death or
serious injury.

WARNING indicates a hazardous situation,
if not avoided, could result in death or seri­ous injury.

CAUTION indicates a hazardous situation
that, if not avoided, could result in minor
or moderate injury.

Failure to comply with the warnings in this
manual can result in severe injury or
death.

Read this entire manual carefully before
operating this vehicle. Do not attempt to
operate this vehicle until you have thor-

ough knowledge of the controls and features.

Spark Arrestor And Use On Public
Lands

The TEXTRON OFF ROAD vehicle has a spark arrester that was
tested and qualified to be in compliance with the USFS standard
5100-1. Federal law requires that this spark arrester be installed
and functional when the vehicle is operated on public lands.

Off road vehicle operation on public lands in the USA is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Go
to www.www.gpo.gov/fdsys to see federal regulations.

Regular inspections and maintenance,
along with good operating techniques, will

capabilities and reliability of this vehicle.

help ensure your safe enjoyment of the

Manufacturer’s Intended Use

The TEXTRON OFF ROAD STAMPEDE 900 is designed and
manufactured for off road use only. Use on public streets, roads or
highways is illegal in most areas and increases the risk of an acci­dent involving other vehicles and people. This vehicle does not
meet FMVSS (Federal Motor Vehicle Safety Standards) for public
street, road or highway use.

Check all laws and regulations before choosing an area to oper­ate the STAMPEDE 900.

Noise Control System

Do not modify the engine, intake or exhaust components. Modifi­cations to these components can affect compliance with
ROHVA1-2016 and local noise level requirements. Modifications
to these components can also affect the emissions control sys­tem.

REPAIR AND SERVICE MANUAL

4X4 ALL TERRAIN VEHICLE

STAMPEDE 900

STARTING MODEL YEAR 2017

CALIFORNIA Proposition 65 Warning

WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which

contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth
defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new
and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates,
all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.

This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifi­cations listed in the following text originate in the USA unless otherwise indicated.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles, Inc. pro­hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehi­cle.

Textron Specialized Vehicles, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without
obligation to include these changes on units sold previously.

The information contained in this manual may be revised periodically by Textron Specialized Vehicles, Inc., and therefore is subject to
change without notice.

TEXTRON SPECIALIZED VEHICLES, INC. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABIL­ITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

These are the original instructions as defined by 2006/42/EC.

CONTACT US:

TEXTRON SPECIALIZED VEHICLES, INC.
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
www.textronoffroad.com

North America:
Technical Assistance & Warranty PHONE: [phone] FAX: [phone]
Service Parts PHONE: [phone]
International:
PHONE: [phone] FAX: [phone]

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GENERAL INFORMATION

The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.

Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehi­cle warranty.

When servicing the engine, all adjustments and replacement components must be per original vehicle specifications in
order to maintain the United States of America Federal and State emission certification applicable at the time of manu­facture.

BATTERY PROLONGED STORAGE

Batteries self-discharge over time. The rate of self-discharge varies depending on the ambient temperature, the age
and condition of the battery.

A fully charged battery will not freeze unless the temperature falls below -75°F (- 60°C).

For winter storage, the battery must be clean, fully charged and disconnected from any source of electrical drain.

BATTERY DISPOSAL

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recy­cling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dis­pose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

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SAFETY INFORMATION

SAFETY INFORMATION

This manual has been designed to assist in the maintenance of the vehicle in accordance with procedures developed
by the manufacturer. Following these procedures and troubleshooting tips will ensure the best possible service from the
product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully
observed:

GENERAL

Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate
and warn against every possible combination of circumstances that may occur. Warnings cannot replace good com­mon sense driving practices. Common sense driving practices do more to prevent accidents and injury than warnings
and instructions can provide.

The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s manual provided with the
purchase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within.

For any questions or concerns, contact your dealer.

Textron Specialized Vehicles, Inc. reserves the right to make design changes without obligation to make these changes
on units previously sold and the information in this manual is subject to change without notice.

Textron Specialized Vehicles, Inc. is not liable for errors in this manual or for incidental or consequential damages that
result from the use of the material in this manual.

This vehicle conforms to the current applicable standard for safety and performance requirements.

This vehicle is designed and manufactured for off road use. It does not conform to Federal Motor Vehicle Safety Stan­dards and is not intended for operation on public streets.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. Do not exceed number of occupants indicated.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle,
decrease it’s stability, increase the speed or extend the stopping distance beyond the fac­tory specification. Such modifications can result in serious personal injury or death.

Modifications that increase the speed and/or weight of the vehicle will extend the braking distance and may reduce the
stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims
responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

Speed should be moderated by the environmental conditions, terrain and common sense.

GENERAL OPERATION

ALWAYS:

• Use the vehicle in a responsible manner and keep the vehicle in safe operating condition.

• Read and observe all warnings and operation instruction labels on the vehicle.

• Follow all safety rules in the area where the vehicle is being operated.

• Reduce speed to compensate for poor terrain or conditions.

• Apply brakes to control speed on steep grades.

• Reduce speed in damp or wet areas.

• Use caution when approaching sharp or blind turns.

• Use caution when driving over loose terrain.

• Use caution when driving in areas where pedestrians are present.

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SAFETY INFORMATION

MAINTENANCE

ALWAYS:

• Replace damaged or missing warning, caution or information labels.

• Maintain the vehicle according to the manufacturer’s periodic service schedule. See SCHEDULED MAINTE-
NANCE CHART on page 166.

• Ensure that repairs are performed by trained and qualified persons.

• Follow the manufacturer’s maintenance procedures.

• Use insulated tools near the battery to prevent sparks or battery explosion.

• Check the polarity of the battery terminals and be sure to rewire the battery correctly.

• Use specified replacement parts. Never use replacement parts of lesser quality.

• Use recommended tools.

• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the
safety of personnel, nor jeopardize the safe operation of the vehicle.

• Lift the vehicle in accordance with the manufacturer’s instructions. Chock the wheels and support the vehicle
with safety stands. Never get under a vehicle that is supported by a jack alone.

• Never service a vehicle in an area where exposed flame is present or persons are smoking.

• Be aware that a vehicle that is not performing properly is a potential hazard and must not be operated.

• Test drive vehicle after repairs or maintenance in a safe area, free of vehicular and pedestrian traffic.

• Keep complete records of the maintenance history of the vehicle.

VENTILATION

ALWAYS:

• Store the vehicle in a well ventilated area to prevent gasoline fumes from accumulating.

• Fuel the vehicle in an area free from flame or sparks. Pay particular attention to natural gas or propane water
heaters and furnaces.

• Service or operate the vehicle in a well ventilated area to prevent the accumulation of exhaust gases.

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

SERIAL NUMBER AND VIN LOCATION

Serial Number Label on Steering Column

Frame VIN
(vehicle frame
under seat)

Front

MAIN SERIAL NUMBER LABEL

Serial Number
Labels under Front
Cowl Access Panel

Certification Statement

Fig. 1 Serial Number and VIN Location

Two serial number and manufacture date code/VIN plates are on the vehicle. One is on the rear crossmember, the other
is on the frame below the seat wrap panel (See Fig. 1).

Design changes take place on an ongoing basis. The information on these labels must be provided to obtain correct
replacement components for the vehicle.

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

STARTING THE VEHICLE WITH A DIS­CHARGED BATTERY

B

The stator is not designed to charge a discharged battery.

If the vehicle is equipped with additional lights and/or a
strobe light that is used when the vehicle is not in motion,
the stator may not be adequate to maintain battery
charge. If the vehicle battery has discharged, it must be
charged with a 12V charger rated at 10 amp or less.
Observe all instructions provided by the manufacturer of
the charger.

SERVICING THE VEHICLE

Do not attempt any type of servicing
operations before reading and
understanding all notes, cautions,

warnings and dangers in this manual.

Any servicing requiring adjustments to be made to
the powertrain while the engine is running must be
made with all four wheels raised.

Wear eye protection when working on the vehicle. In
particular, use care when working around the bat­tery, or using solvents or compressed air.

ROUTINE MAINTENANCE

This vehicle will give years of satisfactory service, if it
receives regular maintenance.

NOTICE: To prolong vehicle life, some maintenance
items must be serviced more frequently on vehicles
used under severe driving conditions such as
extreme temperatures, extreme dust/debris condi­tions, or frequent use with maximum load.

POWERTRAIN MAINTENANCE

Access the powertrain by raising or removing the truck
bed and the seat bottom. Full access to powertrain may
be obtained by removing the skid plate and body panels.
Some service procedures may require the vehicle to be
lifted. See “LIFTING THE VEHICLE” on page 19.

Always install a positive stop to pre­vent severe injury that could result
if the truck bed lift mechanism

should unexpectedly fail.

Use insulated wrenches to prevent the possibility of
a dropped wrench shorting out the battery, which
could result in an explosion and severe personal
injury or death.

To reduce the possibility of causing an electrical
arc, which could result in a battery explosion, turn
off all electrical loads from the battery before
removing any heavy gauge battery wires.

To prevent the possibility of powertrain failure,
never operate the vehicle at full throttle for more
than 4 - 5 seconds while vehicle is in a “no load”
condition.

Before a new vehicle is put into operation, it is recom­mended the items shown in the INITIAL SERVICE
CHART be performed (See Fig. 2).

Vehicle battery must be fully charged before initial use.

ITEM SERVICE OPERATION

Battery Charge battery.

Seats Remove protective plastic covering.

Brakes

Tires

Fuel

Engine Check oil level.

Check operation, adjust if necessary.
Check hydraulic brake fluid level.

Check air pressure, adjust if necessary.
See GENERAL SPECIFICATIONS for
tire pressure.

Fill with correct fuel. See RECOMMENDED
LUBRICANTS AND FLUIDS.

To prevent accidental starting, disconnect the nega­tive battery cable before servicing.

For maintenance procedures relating to the engine, fuel
system, transmission, and rear axle or suspension, refer
to the particular section. See the TABLE OF CONTENTS
for section location.

BRAKES

This vehicle is equipped with four-wheel hydraulic disc
brakes. Check the fluid level at intervals specified in the
SCHEDULED MAINTENANCE CHART. If fluid leaks are
noticed or the brake pedal seems soft, check the fluid
level immediately. If the brake pedal is soft, the brake sys­tem should be bled to remove air from the brake lines.
See “BLEEDING AND FLUSHING” on page 68.

After the vehicle is put into service, the brakes must be
checked by periodically conducting a brake performance
test.

To prevent severe injury or death
resulting from operating a vehicle

with an improperly operating brake
system, the brake system must be properly main­tained. All driving brake tests must be done in a safe
location with regard for the safety of all personnel.

For test method and brake service, refer to BRAKES sec­tion.

Fig. 2 Initial Service Chart

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TIRES

NOTICE: The standard tires on this vehicle are uni­directional. The front tires are narrower than the
rear tires. Tires must not be moved or rotated from
their original position.

Tire condition must be inspected. Inflation pressures must
be checked while the tires are cool. See GENERAL
SPECIFICATIONS on page 161. Be sure to install the
valve dust cap after checking or inflating a tire. See
WHEEL AND TIRE SERVICE on page 53.

LIGHT BULB REPLACEMENT

See LIGHTS on page 137.

CARE AND CLEANING OF VEHICLE

Keeping the vehicle clean is not only beneficial to its
appearance, but can also help extend the life of various
components. See BODY on page 15.

Washing the Vehicle

To prevent damage, do not use a
pressure washer or abrasive sol­vents to clean this vehicle.

• Use an automotive type cleaner or mild soap to wash
the vehicle. Harsh cleaners can scratch the finish.

• Do not use a pressure washer to wash your vehicle.
High water pressure can damage components.

• Use clean or new cloths and pads for washing.
Reused cloths and pads can contain dirt particles
that will scratch the finish.

• Cleaning vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with
a sponge or soft brush. Wipe with a damp cloth.

• Clean any areas where mud or other debris can col­lect. Loosen sediment packed in closed areas to
ease it’s removal, taking care not to chip or otherwise
damage paint.

• Removal of oil, tar, asphalt, etc. requires the use of a
commercially available vinyl/rubber cleaner.

• Lubricate all grease fittings after washing the vehicle.

• Start engine and let it run for a few minutes to dry
any water that may have entered the engine or
exhaust system.

NOTICE: Some products, including insect repellents
and chemicals, will damage plastic surfaces. Do not
allow these types of products to contact the vehicle.

2. To prevent the soap from drying on the vehicle, rinse with clean water frequently.

3. To prevent water spots, dry with a chamois before the water dries.

TEXTRON OFF ROAD does not recommend the use of a
pressure washer. High pressure water can damage com­ponents, chip paint and remove labels. If the use of a
pressure washer cannot be avoided, avoid directing the
water stream at the following items:

• wheel bearings

• body panels

• radiator

• labels and decals

• transmission seals

• switches and controls

• brakes

• electrical components and wiring

Polishing the Vehicle

• Do not use medium to heavy duty compounds on the
finish.

• Use clean or new cloths and pads for polishing. Old
or reused cloths and pads can contain dirt particles
that will scratch the finish.

CANOPY AND WINDSHIELD

The canopy does not provide pro­tection from rollover or falling
objects.

The windshield does not provide protection from
tree limbs or flying objects.

The canopy and windshield are designed for weather pro­tection only. See WEATHER PROTECTION on page 49.

Roll over protection is provided by the ROPS. See ROLL-
OVER PROTECTION SYSTEM (rops) on page 37.

B

1. With an automotive type wash cloth, wash from the top to the bottom.

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TRANSPORTING THE VEHICLE

To prevent personal injury to occu-

B

are secured to trailer.

Do not ride on a vehicle being transported.

This vehicle is not designed to be towed.

It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other suit­able transport.

Always check that the vehicle and contents are secured
before transporting the vehicle. The rated capacity of the
trailer must exceed the weight of the vehicle (See GEN-
ERAL SPECIFICATIONS on page 161. Place the shifter
in the P (park) position and remove the key from the vehi­cle. Secure the vehicle to the trailer using ratchet tie
downs.

pants of other highway vehicles, be
sure that the vehicle and contents

PROLONGED STORAGE

Battery

During periods of storage, the battery must be maintained
to prevent discharge. If a battery is left in a discharged
state, sulfating will cause permanent damage to the bat­tery. In order to prevent damage, the battery should be
recharged.

days or longer requires some simple steps to prevent var­nish, gum and corrosion in the throttle body and in the
engine.

1. Perform all periodic routine maintenance per the periodic service schedule.

2. Place the shifter in the P (park) position.

3. Add a commercially available fuel stabilizer to the
fuel tank. Follow the manufacturer’s mixing instruc­tions.

4. Start the engine and let it run for several minutes in a well ventilated area to allow the fuel stabilizer to be mixed through the fuel system.

5. Allow the engine to run until the system is depleted of fuel.

6. Turn the key switch to the OFF position and remove the key.

7. Remove both ignition coils from the plugs.

8. Remove both spark plugs.

9. Add a conventional cylinder fogging oil or one ounce of 30 weight oil to each spark plug hole.

10. Inspect the spark plugs prior to installation. Replace if needed.

11. Rotate the engine several times with the starter. This will allow the fogging oil to coat the cylinders.

12. Install the ignition coils onto the spark plugs.

Engine

To reduce the possibility of severe
injury or death resulting from a pos­sible explosion:

Do not handle fuel in an area that is not adequately
ventilated. Do not smoke near the fuel tank or refuel
near open flame or electrical items which could pro­duce a spark.

Store the vehicle in a clean, dry area. Do not store in
the same area as a stove, furnace, water heater, or
other appliance that uses a a pilot light or has a
device that can create a spark.

When refueling, inspect the fuel cap for leaks or
breaks that could result in fuel spillage.

Always wear safety glasses while refueling to pre­vent possible eye injury from gasoline or gasoline
vapor.

Keep hands, clothing and jewelry away from moving
parts. Use care not to contact hot objects. Raise the
vehicle and support on jack stands before attempt­ing to run the engine.

Preparing the engine for a prolonged storage period of 30

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

HARDWARE

Periodically inspect the vehicle for loose fasteners. Fas­teners should be tightened with care and in accordance
with the Torque Specifications table (Ref. Fig. 3).

Three classes of standard hardware and three classes of
metric hardware are used in vehicle.

• Grade 2 hardware is unmarked.

TORQUE SPECIFICATIONS

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

Unless otherwise noted in text, tighten all hardware in accordance with this chart.

This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when

installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

BOLT SIZE

Grade 2

Grade 5

Grade 8

BOLT SIZE

Class 5.8
(Grade 2)

Class 8.8
(Grade 5)

Class 10.9
(Grade 8)

5.8

8.8

10.9

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"

4

(5)

6

(8)

6

(8)

M4 M5 M6 M8 M10 M12 M14

1

(2)

2

(3)

3

(4)

8

(11)

13

(18)

18

(24)

2

(3)

4

(6)

6

(8)

15

(20)

23

(31)

35

(47)

4

(6)

7

(10)

10

(14)

24

(33)

35

(47)

55

(75)

10

(14)

18

(24)

25

(34)

• Grade 5 hardware can be identified by the three
marks on the hexagonal head.

• Grade 8 hardware is identified by six marks on the
head.

The class specification is marked on metric hardware.

35

(47)

55

(75)

80

(108)

20

(27)

35

(47)

49

(66)

55

(75)

80

(108)

110

(149)

35

(47)

61

(83)

86

(117)

75

(102)

110

(149)

170

(230)

55

(76.4)

97

(131)

136

(184)

130

(176)

200

(271)

280

(380)

125

(169)

320

(434)

460

(624)

190

(258)

480

(651)

680

(922)

B

Fig. 3 Torque Specifications

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

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TABLE OF CONTENTS

SAFETY INFORMATION

GENERAL ........................................................................................................................ III

GENERAL OPERATION.................................................................................................. III

MAINTENANCE ............................................................................................................... IV

VENTILATION.................................................................................................................. IV

GENERAL INFORMATION AND ROUTINE MAINTENANCE

SERIAL NUMBER AND VIN LOCATION........................................................................ 11

STARTING THE VEHICLE WITH A DISCHARGED BATTERY ..................................... 12

SERVICING THE VEHICLE............................................................................................ 12

ROUTINE MAINTENANCE............................................................................................. 12

POWERTRAIN MAINTENANCE..................................................................................... 12

BRAKES.......................................................................................................................... 12

TIRES.............................................................................................................................. 13

LIGHT BULB REPLACEMENT ....................................................................................... 13

B

SAFETY

CARE AND CLEANING OF VEHICLE............................................................................ 13

Washing the Vehicle .......................................................................................... 13

Polishing the Vehicle .......................................................................................... 13

CANOPY AND WINDSHIELD......................................................................................... 13

TRANSPORTING THE VEHICLE ................................................................................... 14

PROLONGED STORAGE............................................................................................... 14

Battery ................................................................................................................ 14

Engine ................................................................................................................ 14

HARDWARE ................................................................................................................... 15

TORQUE SPECIFICATIONS.......................................................................................... 15

NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................. 17

IMPORTANT SAFETY WARNING.................................................................................. 17

MODIFICATIONS TO VEHICLE ..................................................................................... 17

GENERAL MAINTENANCE............................................................................................ 17

BEFORE SERVICING THE VEHICLE ............................................................................ 17

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LIFTING THE VEHICLE.................................................................................................. 19

Lifting Front of Vehicle ....................................................................................... 19

Lifting Rear of Vehicle ........................................................................................ 19

Lowering Vehicle ................................................................................................ 19

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TABLE OF CONTENTS

BODY

GENERAL........................................................................................................................ 21

B

Painting ...............................................................................................................21

Repairing Scratches ............................................................................................21

Complete Panel Repair .......................................................................................21

Decal Replacement .............................................................................................21

Cowl Removal .....................................................................................................22

Standard Brush Guard Removal .........................................................................24

Premium Brush Guard Removal .........................................................................25

Rocker Panel Removal .......................................................................................26

Side Panel and Rear Fender Liner Removal ......................................................26

Quarter Panel and Front Fender Liner Removal .................................................26

Door Removal .....................................................................................................27

Door Handle and Latch Assembly Removal .......................................................28

FRAME

Striker Plate Removal .........................................................................................29

Floorboards .........................................................................................................29

SEATING ......................................................................................................................... 30

Seat Bottom Removal .........................................................................................31

Seat Back Removal ............................................................................................31

Seat Closeout Removal ......................................................................................31

EXTENDED CAB ............................................................................................................. 32

Cargo Tray Removal ...........................................................................................33

Rear Closeout Panel Removal ............................................................................33

Front Closeout Panel Removal ...........................................................................33

Extended Cab Door Removal .............................................................................33

Skid Plate Removal .............................................................................................34

GENERAL........................................................................................................................ 38

Door Hinge Removal ...........................................................................................38

Dash Support Removal .......................................................................................38

Hand Hold Removal ............................................................................................39

Front Shock Tower Brace Removal ....................................................................39

Rear Shock Tower Brace Removal .....................................................................39

Seat Frame Removal ..........................................................................................41

B-Pillar Crossmember Removal ..........................................................................41

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ROLLOVER PROTECTION SYSTEM (ROPS)

Removing the ROPS as a Complete Unit .......................................................... 44

INSTALLING ROPS COMPONENTS ............................................................................. 44

A. ROPS Side Tube Installation ......................................................................... 44

B. ROPS Extended Cab Tubes Installation ........................................................ 44

C. Rear Cross-tube Installation .......................................................................... 44

E. Front Cross-tube Installation .......................................................................... 46

F. Seat Back Support Installation ....................................................................... 46

G. Tighten ROPS Hardware ............................................................................... 46

SEATBELT INSTALLATION ........................................................................................... 47

Headrest Installation .......................................................................................... 48

TRUCK BED

TRUCK BED REMOVAL................................................................................................. 52

Decal Replacement ............................................................................................ 53

TABLE OF CONTENTS

B

WEATHER PROTECTION

GENERAL ....................................................................................................................... 55

CANOPY ......................................................................................................................... 55

Installing Mounting Brackets .............................................................................. 55

Installing Canopy Clamps .................................................................................. 56

Installing the Canopy .......................................................................................... 57

WHEELS AND TIRES

WHEEL AND TIRE SERVICE......................................................................................... 59

Tire Tread Depth ................................................................................................ 60

Tire Repair ......................................................................................................... 60

Tire Replacement ............................................................................................... 60

Wheel Removal .................................................................................................. 60

Wheel Installation ............................................................................................... 60

BRAKES

MAINTENANCE .............................................................................................................. 64

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Daily Brake Performance Test ........................................................................... 64

Brake System Inspection ................................................................................... 64

Brake Fluid ......................................................................................................... 64

MASTER CYLINDER ...................................................................................................... 65

Master Cylinder Replacement ............................................................................ 65

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TABLE OF CONTENTS

Brake Pad Replacement .....................................................................................66

Rotor Replacement .............................................................................................67

B

FRONT CV SHAFT, SUSPENSION AND STEERING

BLEEDING AND FLUSHING ........................................................................................... 68

Bleeding ..............................................................................................................68

Bleeding Sequence .............................................................................................68

Flushing the Brake System .................................................................................69

BRAKE AND ACCELERATOR PEDALS ......................................................................... 69

Brake Pedal Removal And Installation ................................................................69

Accelerator Pedal Removal ................................................................................70

FRONT SUSPENSION .................................................................................................... 74

Maintenance .......................................................................................................74

Wheel Bearing Test ............................................................................................74

Front Hub Removal .............................................................................................74

Front Spindle Removal .......................................................................................75

FRONT AXLE .................................................................................................................. 77

CV Shaft Replacement .......................................................................................77

CV Joint Boot Replacement ................................................................................77

Front Strut Assembly Replacement ....................................................................77

Lower Control Arm Assembly Replacement .......................................................78

Upper Control Arm Assembly Replacement .......................................................79

Stabilizer Bar Removal .......................................................................................80

FRONT DIFFERENTIAL ................................................................................................. 80

Front Differential Oil Check .................................................................................80

Front Differential Oil Replacement ......................................................................81

Front Differential Replacement ...........................................................................81

STEERING....................................................................................................................... 82

Steering Wheel Replacement .............................................................................84

Steering Column Removal ..................................................................................85

Steering Shaft Replacement (Non-EPAS) ..........................................................85

Electric Power Assist System (EPAS) (If Equipped) ...........................................86

Steering Rack Replacement ...............................................................................87

Rack Ball Joint Replacement ..............................................................................87

MAINTENANCE............................................................................................................... 88

Wheel Alignment .................................................................................................88

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668061

STEERING WHEEL ........................................................................................................ 89

RIDE HEIGHT ADJUSTMENT........................................................................................ 89

REAR AXLE AND SUSPENSION

REAR SUSPENSION...................................................................................................... 92

Maintenance ....................................................................................................... 92

Wheel Bearing Test ............................................................................................ 92

Hub Removal ..................................................................................................... 92

Rear Spindle Removal ....................................................................................... 93

CV Shaft Replacement ....................................................................................... 94

CV Joint Boot Replacement ............................................................................... 94

Rear Strut Assembly Replacement .................................................................... 95

Lower Control Arm Assembly Replacement ....................................................... 95

Upper Control Arm Assembly Replacement ....................................................... 96

Stabilizer Bar Removal ....................................................................................... 96

TABLE OF CONTENTS

B

REAR DIFFERENTIAL.................................................................................................... 97

Oil Change ......................................................................................................... 97

Rear Differential Oil Check ................................................................................. 97

Rear Differential Oil Replacement (Upper Chamber) ......................................... 97

Rear Differential Oil Replacement (Lower Chamber) ......................................... 98

Rear Differential Replacement ........................................................................... 99

Adjusting the Shift Lever Cable ........................................................................ 102

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

GENERAL ..................................................................................................................... 105

CLUTCHES................................................................................................................... 105

Primary Clutch .................................................................................................. 105

Secondary Clutch ............................................................................................. 105

Increased Load ................................................................................................ 105

Equilibrium ....................................................................................................... 105

CVT BELT ..................................................................................................................... 107

CVT Belt Break-in ............................................................................................ 107

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CVT Belt Inspection ......................................................................................... 107

CVT Belt Replacement ..................................................................................... 107

Primary Clutch Removal ................................................................................... 107

Primary Clutch Installation ................................................................................ 108

Secondary Clutch Removal .............................................................................. 109

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5

TABLE OF CONTENTS

Secondary Clutch Installation ...........................................................................109

Draining the CVT ..............................................................................................109

B

PROP-SHAFT

GENERAL .........................................................................................................112

Prop-shaft Maintenance ....................................................................................112

Prop-shaft Removal ..........................................................................................112

ENGINE

GENERAL...................................................................................................................... 116

ENGINE DESCRIPTION................................................................................................ 116

Engine Specifications ........................................................................................116

ENGINE BREAK-IN ....................................................................................................... 116

ENGINE MAINTENANCE .............................................................................................. 116

ENGINE OIL .................................................................................................................. 116

CHANGING ENGINE OIL AND FILTER ........................................................................ 117

AIR FILTER MAINTENANCE ........................................................................................ 118

SPARK PLUGS.............................................................................................................. 119

ENGINE COMPRESSION TEST ................................................................................... 120

ENGINE REMOVAL....................................................................................................... 121

EXHAUST SYSTEM REMOVAL.................................................................................... 123

AIR INTAKE

ENGINE AIR INTAKE .................................................................................................... 128

Engine Oil Type and Capacity ..........................................................................116

Checking the Engine Oil Level ..........................................................................116

Remove Engine Oil ...........................................................................................117

Replace the Oil Filter ........................................................................................118

Refill Engine Oil ................................................................................................118

Spark Plug Inspection and Replacement ..........................................................119

Air Filter Maintenance .......................................................................................128

Air Filter Housing Removal ...............................................................................128

COOLING SYSTEM

COOLING SYSTEM....................................................................................................... 132

Coolant ..............................................................................................................132

Reservoir Coolant Level ....................................................................................132

Radiator Coolant Level .....................................................................................132

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Coolant Replacement ....................................................................................... 133

Coolant Reservoir Removal ............................................................................. 133

Radiator and Cooling Fan ................................................................................ 133

Radiator Removal ............................................................................................ 134

Thermostat and Water Pump ........................................................................... 135

FUEL SYSTEM

GENERAL ..................................................................................................................... 138

FUEL ............................................................................................................................. 138

FUEL SYSTEM SERVICE ............................................................................................ 138

Fuel Tank Removal .......................................................................................... 138

Fuel Pump Assembly ....................................................................................... 139

ELECTRICAL SYSTEM

MAIN HARNESS........................................................................................................... 141

TABLE OF CONTENTS

B

Power Supply ................................................................................................... 141

Circuits and Controls ........................................................................................ 141

Testing Engine Starting Circuit ......................................................................... 141

VOLTAGE TEST FOR BATTERY................................................................................. 142

BATTERY...................................................................................................................... 142

Battery Cleaning ............................................................................................... 142

Battery Charging .............................................................................................. 142

Battery Storage ................................................................................................ 142

Battery Removal ............................................................................................... 143

LIGHTS ......................................................................................................................... 143

Headlight Bulb Replacement ............................................................................ 143

Headlight Beam Adjustment ............................................................................. 144

Brake Light Bulb Replacement ......................................................................... 144

Information Display Removal ........................................................................... 145

Engine Control Unit (ECU) ............................................................................... 145

Voltage Regulator Removal ............................................................................. 149

Solenoid Controller Removal ............................................................................ 149

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WIRING DIAGRAMS..................................................................................................... 150

FAULT TESTING

General ............................................................................................................ 161

Voltmeter .......................................................................................................... 161

Repair and Service Manual

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TABLE OF CONTENTS

Continuity Check ...............................................................................................161

Testing a Switch for Continuity .........................................................................161

B

STARTER FAULT TESTING ......................................................................................... 164

SUSPENSION AND STEERING FAULT TESTING ...................................................... 164

GENERAL SPECIFICATIONS

SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE CHART ........................................................................ 172

RECOMMENDED LUBRICANTS AND FLUIDS............................................................ 174

Testing the Ignition System ...............................................................................161

Testing Fuses ...................................................................................................161

Powertrain Performance ...................................................................................162

Initial Service Requirements .............................................................................171

Severe Use Conditions .....................................................................................171

REPLACEMENT OF MAINTENANCE ITEMS............................................................... 174

APPENDIX A

FAULT CODES................................................................................................................. A

DIAGNOSTIC MANUAL.................................................................................................... A

EPAS FAULT CODES ...................................................................................................... C

CAN ..................................................................................................................... E

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Notes:

TABLE OF CONTENTS

668061

Repair and Service Manual

9

TABLE OF CONTENTS

Notes:

10

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SAFETY

NOTICES, CAUTIONS, WARNINGS
AND DANGERS

The following symbols appear throughout this manual
and on your vehicle. Your safety is involved when these
symbols are used. Become familiar with their meanings
before reading the manual.

DANGER indicates a hazardous situa­tion that, if not avoided, will result in
death or serious injury.

WARNING indicates a hazardous
situation, if not avoided, could
result in death or serious injury.

CAUTION indicates a hazardous
situation that, if not avoided, could
result in minor or moderate injury.

IMPORTANT SAFETY WARNING

In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.

It is impossible to anticipate all possible component fail­ures or the manner in which each component may fail.

Be aware that a vehicle requiring repair indicates that the
vehicle is no longer functioning as designed and there­fore should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diag­nosing, removing or replacing any components that are
not operating correctly, take the time to consider the
safety ramifications if the component should move unex­pectedly.

Some components are heavy, spring loaded, highly cor­rosive, explosive or may produce high amperage or
reach high temperatures. Exposure to battery acid and
hydrogen gas could result in serious bodily injury to the
technician/mechanic and bystanders if not treated with
utmost caution. Be careful not to place hands, face, feet
or body in a location that could expose them to injury
should an unexpected situation occur.

Always use the appropriate tools listed in the tool list and
wear approved safety equipment.

MODIFICATIONS TO VEHICLE

Do not modify the vehicle in any manner that will change
the weight distribution of the vehicle.

Changes to the weight distribution
or the center of gravity may make

the vehicle unstable or prone to
rollover which could result in injury or death to the
operator or passengers.

GENERAL MAINTENANCE

To prevent severe injury or death

resulting from improper servicing

techniques, do not attempt any
type of servicing operations before reading and
understanding all notices, cautions and warnings in
this manual.

When maintenance procedures or inspection are per­formed, ensure the safety of the technician/mechanic or
bystanders, and to prevent damage to the vehicle.

Always read and understand the entire relevant manual
section (chapter) before attempting any inspection or
service.

BEFORE SERVICING THE VEHICLE

Before inspecting or servicing a vehicle, read and under­stand the following warnings:

Before working on the vehicle,

remove all jewelry.

Make sure that clothing or hair cannot become
caught in the moving parts of the powertrain.

Do not contact hot objects.

Before attempting to operate or adjust the power­train, the vehicle must be raised and supported on
jack stands.

Wear OSHA approved clothing and eye protection
when working on anything that could expose the
body or eyes to potential injury. In particular, use
care when working with or around batteries, com­pressed air or solvents.

668061

Always turn the key switch to OFF and remove the
key before disconnecting a live circuit.

When connecting battery cables, pay particular
attention to the polarity of the battery terminals.
Never confuse the positive and negative cables.

The shifter must always be placed in the P (park)
position, except for cases where the powertrain

Repair and Service Manual

11

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

must be allowed to rotate or service is being per­formed on the brake system.

If repairs are to be made that will require welding or

B

cutting, the battery and fuel tank must be removed
and the fuel system drained.

To prevent an explosion that could result in severe
injury or death, keep all smoking materials, open
flame or sparks away from gasoline and battery.

Never operate the starter with the spark plugs
removed unless the ignition system has been dis­abled and the engine/exhaust are cold. Fuel
expelled from the cylinders can ignite by the igni­tion system or the hot exhaust system.

Never work on a hot engine.

Never test the ignition system without either con­necting the spark plug lead to a tester or a spare
grounded spark plug.

If the spark function is to be observed at the spark
plug, install a spare spark plug into the open cylin­der before operating the starter.

Never test the function of a fuel pump in the vicinity
of a hot engine or other source of flame or combus­tion.

Verify that the fuel lines are correctly installed
before starting the engine. See the FUEL SYSTEM
section.

Be sure that the key switch is off and all electrical
accessories are turned off before working on vehi­cle.

ing with clear water. Contact a physician immedi­ately.

Wear eye protection when working
on the vehicle. In particular, be care­ful when working around batteries,
or using solvents or compressed
air.

Electrolyte spills must be neutralized with a solution
of 1 tablespoon (15 ml) sodium bicarbonate (baking
soda) dissolved in 1 quart (1 liters) of water and
then flushed with water.

Use insulated wrenches to prevent the possibility of
a dropped wrench from shorting out a battery,
which could result in an explosion and severe per­sonal injury or death.

Aerosol containers of battery terminal protectant
must be used with extreme care. Insulate metal con­tainer to prevent can from contacting battery termi­nals which could result in an explosion.

Never work around or operate a vehicle in an envi­ronment that does not ventilate exhaust gases from
the area.

Carbon monoxide is an odorless gas that is formed
as a natural part of the incomplete combustion of
hydrocarbon fuels. Carbon monoxide is a danger­ous gas that can cause unconsciousness and is
potentially lethal.

The following are symptoms of carbon monoxide
inhalation:

Dizziness

The battery should always be removed before any
servicing or repairs that could generate sparks.

Never disconnect a circuit under load at a battery
terminal.

Batteries are heavy. Use
proper lifting techniques when
moving them. Always lift the
battery with a commercially
available battery lifting device.
Use care not to tip the battery
when removing or installing;
spilled electrolyte can cause

burns and damage.

The electrolyte in a battery is an acid solution which
can cause severe burns to the skin and eyes. Treat
all electrolyte spills to the body and eyes by flush-

Vomiting

Intense headache

Muscular twitching

Weakness and sleepiness

Throbbing in temples

If experiencing any of these symptoms, get fresh air
immediately.

12

Repair and Service Manual

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SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LIFTING THE VEHICLE

Tool List Qty.

Floor Jack.................................................................... 1

Jack Stand................................................................... 4

Chocks ........................................................................ 4

To reduce the possibility of severe
injury or death from a vehicle falling
from a jack:

Place shifter in the P (park) position.

Always place chocks in front and behind the
wheels.

Be sure the vehicle is on a firm and level surface.

Never get under a vehicle while it is supported only
by a jack.

Use jack stands and test the stability of the vehicle
on the stands.

The vehicle is extremely unstable during the lifting
process.

When lifting the vehicle, position jacks and jack
stands only on the areas indicated.

4. Install a jack stand under each side of the vehicle frame just in front of the rear wheels.

5. Lower the vehicle until it rests on the jack stands.

6. Remove the jack.

7. Confirm that the vehicle is stable on the jack stands before proceeding with any service.

Lowering Vehicle

1. Make sure chocks are still in place on any wheels that remain on the ground.

2. Put the jack in the same location that was used to raise the vehicle.

3. Raise the vehicle enough to remove the jack stands.
Remove the jack stands from underneath the vehi­cle.

4. Slowly lower the vehicle to the ground and remove the jack.

FRONT

B

Remove payload from vehicle before lifting. No per­son(s) should be in or on the vehicle during the lift­ing process.

NOTICE: If under-vehicle access is required, remove
the skid plate prior to beginning the lifting process.

Lifting Front of Vehicle

1. Chock the rear wheels to keep the vehicle from roll­ing backward (Ref. Fig. 2).

2. Put a jack under the center of the vehicle frame at the differential mounting plate (Ref. Fig. 1).

3. Raise the vehicle with the jack.

4. Install a jack stand under each side of the vehicle frame just behind the front wheels.

5. Lower the vehicle until it rests on the jack stands.

6. Remove the jack.

7. Confirm that the vehicle is stable on the jack stands before proceeding with any service.

Lifting Rear of Vehicle

1. Chock the front wheels to keep the vehicle from roll­ing forward (Ref. Fig. 2).

2. Put a jack under the center of the vehicle frame at the hitch mounting plate (Ref. Fig. 1).

3. Raise the vehicle with the jack.

REAR

Fig. 1 Lifting the Vehicle

Fig. 2 Wheel Chocks

668061

Repair and Service Manual

13

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

14

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BODY

GENERAL

NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise
specified. See HARDWARE on page ix.

Body components can be replaced with a minimum of
special tools. Most body components are held in position
with removable plastic rivets and standard hardware.

Painting

Follow the paint manufacturer’s recommendations for
specific painting procedures and information.

All painting must be done in an
area with adequate ventilation to
safely disperse harmful vapors.

Wear eye protection and respirator, following man­ufacturer’s instructions, to protect from over spray
and airborne mist.

NOTICE: Provide protection from over spray to vehi-

cle and surrounding area.

Repairing Scratches

To repair minor scratches, the following steps must be
taken:

1. Thoroughly clean the surface to be repaired with alcohol and allow to dry.

2. Use a brush to apply a minimum of two coats of touch up paint to the damaged area. Allow 30 - 45 minutes between coats; increase to 45 - 60 minutes in higher humidity. The painted area must be slightly higher than the surface of the part.

3. Use 400 grit “wet” sand paper to blend painted area level with the rest of the part being repaired.

4. Use a polishing compound (3M Finesse or automo­tive grade) to renew gloss and to further blend and
transition newly painted surface.

5. Clean with alcohol and allow to dry.

6. Optional but recommended; Apply clear coat to renew and protect depth of finish.

7. Wax or polish with a Carnauba base product, avail­able at any automotive parts distributor. Do not wax
flat finishes.

To repair large scratches, the following steps must be
taken:

1. Thoroughly clean the surface to be repaired with alcohol, and allow to dry.

2. Apply tape to the area surrounding the damaged area to prevent over spray of paint.

3. Shake the aerosol paint a minimum of one minute to mix thoroughly and achieve the best color match.

4. Apply paint in light even overlapping strokes. Multi­ple coats can be applied to provide adequate cover­age and finish.

5. Allow paint to dry overnight.

6. Use 400 grit “wet” sand paper to blend painted area level with the surface of the part being repaired.

7. Use a polishing compound (3M Finesse or automo­tive grade) to renew gloss and to further blend and
transition newly painted surface.

8. Clean with alcohol, and allow to dry.

9. Optional but recommended; Apply clear coat to renew and protect depth of finish.

10. Wax or polish with Carnauba base product, avail­able at any automotive parts distributor. Do not wax
flat finishes.

Complete Panel Repair

If large panels or areas must be painted, touch up paint
is not recommended. In such cases, professional paint­ing or panel replacement is necessary. Body panel
replacement is sometimes more cost effective than paint­ing. Painting can be done by any body panel repair shop
with experience in painting thermoplastic Polyolefin
(TPO) panels. TPE is a common material in modern
automobile body panels, and all body panel repair shops
should be familiar with the materials and processes
required.

The finish will include an application of a primer coat, a
base color coat, and a clear coat.

Decal Replacement

Tool List Qty.

Alcohol .................................................................... A/R

Clean Cloth ................................................................. 1

Squeegee.................................................................... 1

When replacing decals on the body panels:

1. Prepare the surface by cleaning with alcohol and a clean cloth. Allow the surface to dry.

2. Peel away the decal backing and apply to the sur­face.

3. Use a squeegee to smooth out the decal and remove any air pockets trapped under the decal. A needle can be used to puncture any remaining air pockets that cannot be otherwise removed.

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15

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Cowl Removal

B

7

28

2

1

27

8

25

3

24

Fig. 1 Cowl and Front Fascia

Tool List Qty.

Ratchet ........................................................................ 1

Torx Bit, T30 ................................................................ 1

Pry Bar......................................................................... 1

Screwdriver, Flat Tip....................................................1

1. Unlock the quarter-turn fasteners on the hood. Open the hood (2) to vertical and pull straight up to remove (See Fig. 1).

2. Remove the nuts (25) that secure the grill (24) to the front fascia (3). Remove the grill.

3. Disconnect the headlights from the wire harness.

4. Remove the plastic rivets (8) and screws (27) that secure the fascia to the cowl (1). Remove the fascia from the vehicle.

5. Remove screws (7) and plastic rivets (8) that secure the cowl (1) to the frame. Remove the cowl.

6. Installation is the reverse order of removal.

NOTICE: The cowl can be removed with the front
fascia attached to the cowl or it can be removed
separately.

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BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Dash Removal

15

14

B

1

6

4

Fig. 2 Dash and Front Bulkhead

Tool List Qty.

Pry Bar ........................................................................ 1

Screwdriver, Phillips Head........................................... 1

Ratchet........................................................................ 1

Torx Bit, T30 ................................................................ 1

Wrench, 13mm ............................................................ 1

1. Remove the cowl. See Cowl Removal on page 16.

2. Remove plastic ratchet fasteners (15) that secure the display cover (14) to the dash (1). Remove the cover (See Fig. 2).

3. Remove the instrument display, USB outlet, key switch and control switches. See ELECTRICAL SYSTEM on page 135.

4. Remove the passenger hand hold. See FRAME on page 31.

6

5

Front of Vehicle

5. Remove the rocker panel. See Rocker Panel Removal on page 20.

6. Remove the quarter panels and fender liners. See Quarter Panel and Front Fender Liner Removal on page 20.

7. Remove the steering wheel and adjustment strut. See Steering Wheel Replacement on page 78.

8. Loosen the jam nut and remove the shifter knob.

9. Remove the floorboards. See Floorboards on page 23.

10. Remove the bolts (6) the secure the front bulkhead (4) to the bottom of the dash (1).

11. Remove the bolts (6) that secure the dash to the frame.

12. Remove the dash from the vehicle.

13. Installation is the reverse order of disassembly.

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Repair and Service Manual

17

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Standard Brush Guard Removal

B

2

4

1

3

Fig. 3 Standard Brush Guard

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 17mm.............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove two bolts (3) and nuts (4) that secure the brush guard (1) to the bracket (2) (See Fig. 3).

2. Remove four bolts (3) and nuts (4) that secure the brush guard (1) to the frame.

3. Remove the brush guard.

4. Installation is the reverse order of removal.

5. Tighten the hardware to torque specified below.

Item Torque Specification

3 30 - 33 ft. lbs. (40 - 45 Nm)

Front of Vehicle

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Repair and Service Manual

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Premium Brush Guard Removal

4

3

16

B

15

20

4

1

3

3

3

14

21

11

3

3

6

22

4

4

2

12

Front of Vehicle

Fig. 4 Premium Brush Guard

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 17mm.............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the two bolts (20) that secure the upper shield (11) to the shield mounting bracket (16) (See Fig. 4).

2. Remove the four bolts (21) that secure the upper shield (11) to the lower shield (12). Remove the upper shield (11).

3. The grill (14) can be removed from the upper shield by removing two plastic rivets (15).

668061

Repair and Service Manual

4. Remove the two bolts (22) that secure the lower shield (12) to the frame. Remove the lower shield (12).

5. Remove the bolts (3) and nuts (4) that secure the brush guard (1) to the bracket (2).

6. Remove the bolts (3) and nuts (4) that secure the brush guard (1) to the frame.

7. Remove the brush guard.

8. Installation is the reverse order of removal.

9. Tighten the hardware to torque specified below.

Item Torque Specification

3, 20, 21, 22 30 - 33 ft. lbs. (40 - 45 Nm)

19

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Rocker Panel Removal

B

5

Front of Vehicle

7

Fig. 5 Rocker Panel

Tool List Qty.

Screwdriver, Flat Tip....................................................1

Torx Bit, T30 ................................................................ 1

Ratchet ........................................................................ 1

1. Remove the two screws (5) that secure the rocker panel (7) to the frame (See Fig. 5).

2. Remove the two plastic rivets (13) that secure the rocker panel to the frame. Remove the rocker panel.

3. Installation is the reverse order of removal.

13

Tool List Qty.

Screwdriver, Flat Tip ....................................................1

Torx Bit, T30.................................................................1

Ratchet.........................................................................1

1. Remove the rocker panel. See Rocker Panel Removal on page 20.

2. Remove the screw (9) and plastic rivets (13) that secure the side panel (3) to the frame (See Fig. 6). Remove the side panel.

3. Remove the screws (9) that secure the rear fender liner (5) to the frame. Remove the rear fender liner.

4. Installation is the reverse order of removal.

Quarter Panel and Front Fender Liner Removal

Tool List Qty.

Screwdriver, Flat Tip ....................................................1

Torx Bit, T30.................................................................1

Ratchet.........................................................................1

1. Remove the rocker panel. See Rocker Panel Removal on page 20.

2. Remove the door. See Door Removal on page 21.

3. Remove the plastic rivets (13) and screw (9) that secure the front fender liner (11) to the quarter panel (1) (See Fig. 7). Remove the front fender liner.

4. Remove the plastic rivets (14) and screws (10) that secure the quarter panel to the frame. Remove the quarter panel

Side Panel and Rear Fender Liner Removal

9

9

5

3

Front of Vehicle

Fig. 6 Side Panel and Rear Fender Liner

13

20

Repair and Service Manual

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

.

Cowl

14

1

10

11

13

9

Front of Vehicle

Tool List Qty.

Ratchet ........................................................................1

Socket, 15mm..............................................................1

Wrench, 15mm ............................................................1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (15), nuts (16) and hinge plate (8) that secure the door (1) to the upper and lower door hinges (See Fig. 8).

2. Remove the door from the vehicle.

3. Installation is the reverse order of removal.

4. Tighten the hardware to torque specified below.

Item Torque Specification

15, 16 22 - 26 ft. lbs. (30 - 35 Nm)

5. Adjust the position of the striker plate or door as needed after installation to allow the doors to latch properly.

B

Fig. 7 Quarter Panel and Front Fender Liner

Door Removal

Front of Vehicle

16

1

8

15

668061

Fig. 8 Door

Repair and Service Manual

21

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Door Handle and Latch Assembly Removal

B

Door

15

24

Front of Vehicle

20

3

Fig. 9 Door Handle and Latch Assembly

Tool List Qty.

Ratchet ........................................................................ 1

Torx Bit, T30 ................................................................ 1

Torx Bit, T27 ................................................................ 1

Socket, 15mm.............................................................. 1

Wrench, 15mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the screws (20) that secure the cover plate (1) to the door (See Fig. 9).

2. Remove the screws (12) that secure the cover plate (1) to the latch mount bracket (10) and to the door.

3. Remove the door handle assembly.

26

12

1

12

21

25

26

19

19

7

4. Remove the screws (3) and nuts (21) that secure the cover plate to the door lever assembly.

5. Remove the screws (7) that secure the latch mecha­nism to the latch mount bracket (10).

6. The push rod (25) can be removed by twisting the clips (26) to the open position.

7. Installation is the reverse order of removal.

8. Tighten the hardware to torque specified below.

5

10

22

Repair and Service Manual

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Floorboards

Item Torque Specification

3, 20, 21 11 - 15 ft. lbs. (15 - 20 Nm)

12 11 - 15 ft. lbs. (15 - 20 Nm)

7 5 - 6 ft. lbs. (7 - 8 Nm)

Seat Closeout

11

B

Striker Plate Removal

41

42

43

Front of Vehicle

Fig. 10 Striker Plate

Tool List Qty.

Socket, 7/16” ............................................................... 1

Ratchet........................................................................ 1

Wrench, 7/16”.............................................................. 1

Torque Wrench, ft. lbs. ................................................ 1

1. Remove the bolts (42) and nuts (43) that secure the striker plate (41) to the ROPS tube (See Fig. 10).

2. Installation is the reverse order of removal.

3. Adjust the position of the striker plate or door as needed after installation to allow the doors to latch properly.

4. Tighten the hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

42, 43 15 - 18 ft.lbs. (20 - 25 Nm)

5

6

4

4

6

Front of Vehicle

Bulkhead

Tool List Qty.

Screwdriver, Flat Tip ....................................................1

Torx Bit, T30.................................................................1

Ratchet ........................................................................1

1. Remove the rocker panel. See Rocker Panel Removal on page 20.

2. Remove the plastic rivets (11) that secure the cup holder (5) to the seat closeout and the prop-shaft cover (4) (See Fig. 11). Remove the cup holder.

3. Remove the screws (6) that secure the prop-shaft cover (4) to the floorboards. Remove the cover.

4. Remove the screws (9) that secure the floorboards to the frame.

5. Remove the screws (6) that secure the floorboards to the bulkhead. Remove the floorboards.

6. Installation is the reverse order of removal.

10

6

Fig. 11 Floorboards

9

10

9

1

668061

Repair and Service Manual

23

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SEATING

B

21

21

14

12

10

1

6

9

Fig. 12 Seat Components

Seat Frame

Front of Vehicle

24

Repair and Service Manual

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Seat Bottom Removal

1. The seat bottom (1) is removed by grasping the front edge of the seat bottom and pulling up and out of the vehicle. (See Fig. 12)

2. To install the seat bottom, align the alignment pins
on the bottom, front of the seat bottom with the rub­ber grommets on the seat frame. Push the seat bot­tom down into place.

Seat Back Removal

Tool List Qty.

Ratchet........................................................................ 1

Torx Bit, T45 ................................................................ 1

Torque Wrench, in. lbs................................................. 1

1. Remove the four bolts (21) that secure the seat back (14) to the seat back supports (12) (See Fig. 12).

2. Remove the seat back from the vehicle.

3. Installation is the reverse of removal.

4. Tighten the hardware to the torque specified below:

B

Item Torque Specification

21 15 - 20 in. lbs. (20 - 27 Nm)

Seat Closeout Removal

Tool List Qty.

Ratchet........................................................................ 1

Torx Bit, T30 ................................................................ 1

Screwdriver, Flat Tip.................................................... 1

1. Remove the four bolts (9) that secure the bottom of the seat closeout (6) to the seat frame (See Fig. 12).

2. Remove the four plastic rivets (10) that secure the top of the seat closeout (6) to the seat frame.

3. Remove the seat closeout from the vehicle.

4. Installation is the reverse of removal.

668061

Repair and Service Manual

25

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

EXTENDED CAB

B

10

11

3

Heat
Shields

8

11

Heat
Shields

10

4

9

11

9

2

11

1

14

15

Front of Vehicle

26

Seat Frame

B-pillar

Crossmember

Fig. 13 Extended Cab Components

Repair and Service Manual

Frame

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Cargo Tray Removal

Tool List Qty.

Ratchet........................................................................ 1

Torx Bit, T30 ................................................................ 1

Screwdriver, Flat Tip.................................................... 1

Torque Wrench, in. lbs................................................. 1

1. Remove the plastic rivets (11) that secure the edges of the cargo tray (3) to the side panels (See Fig. 13).

2. Remove the screws (10) that secure the cargo tray to frame and the cab closeout panel (2). Lift the cargo tray out of the vehicle.

3. Installation is the reverse order of removal.

NOTICE: Make sure that the heat shields are attached
to the cargo tray components before installation.

4. Tighten the hardware to the torque specified below:

Item Torque Specification

10 44 - 72 in. lbs. (5 - 8 Nm)

Rear Closeout Panel Removal

Tool List Qty.

Ratchet........................................................................ 1

Torx Bit, T30 ................................................................ 1

Screwdriver, Flat Tip.................................................... 1

Torque Wrench, in. lbs................................................. 1

1. Remove the screws (4) that secure the top edges of the rear closeout panel (2) to the ROPS tubes (See Fig. 13).

2. Remove the plastic rivets (11) that secure the panel (2) to the bracket (1). Remove the rear closeout panel.

3. Installation is the reverse order of removal.

4. Tighten the hardware to the torque specified below:

Item Torque Specification

3. Remove the plastic rivets (11) that secure the front closeout panel (8) to the seat frame and B-pillar crossmember (See Fig. 13).

4. Remove the plastic rivets (11) that secure the top of
the front closeout panel (8) to the B-pillar crossmem­ber.

5. Remove the front closeout panel.

6. Installation is the reverse order of removal.

Extended Cab Door Removal

Tool List Qty.

Ratchet ........................................................................1

Torx Bit, T30.................................................................1

Screwdriver, Flat Tip ....................................................1

Torque Wrench, in. lbs.................................................1

1. Remove hinge covers (30) from the hinges (37) (See Fig. 14).

2. Remove the screws (40) that secure the hinges (37) to the door panels (33). Remove the door panel (33) from the vehicle.

3. Installation is the reverse order of removal.

4. Tighten the hardware to the torque specified below:

Item Torque Specification

40 13 - 20 in. lbs. (1.5 - 2.3 Nm)

33

Front of Vehicle

37

B

4 44 - 72 in. lbs. (5 - 8 Nm)

Front Closeout Panel Removal

Tool List Qty.

Ratchet........................................................................ 1

Torx Bit, T30 ................................................................ 1

1. Remove the air filter and CVT air intake hoses from
the front panel. See the CVT and AIR INTAKE sec­tions.

2. Disconnect the electric control unit. See the ELEC­TRICAL SYSTEM section.

668061

Repair and Service Manual

40

30

Side Panel

Fig. 14 Extended Cab Doors

27

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Skid Plate Removal

B

Front of Vehicle

Fig. 15 Skid Plate

Tool List Qty.

Ratchet ........................................................................ 1

Torx Bit, T30 ................................................................ 1

Torque Wrench, in lbs.................................................. 1

1. Remove the screws (4) that secure the skid plate (1) and skid guard bracket (2) to the bottom of the frame (See Fig. 15).

2. Slide the rear of the skid plate forward and down off the rear frame weldment.

3. Installation is the reverse order of removal.

1

2

4. Tighten the hardware to the torque specified below:

4

Item Torque Specification

4 20 - 44 in. lbs. (2 - 5 Nm)

28

Repair and Service Manual

668061

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

668061

Repair and Service Manual

29

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

30

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FRAME

31

5

4

3

2

16

18

31

8

78

14

6

1

668061

19

18

30

20

30

22

27

23

19

26

22

24

Front of Vehicle

Fig. 1 Frame Overview

Repair and Service Manual

29

31

FRAME

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

GENERAL

NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise

B

specified. If torque values are not specified, refer to
the Torque Specifications table. See TORQUE
SPECIFICATIONS on page ix.

To access the frame components, the body panels must
be removed. See BODY on page 15.

Door Hinge Removal

10

Front of Vehicle

16

18

11

11

30

23

22

29

4. To remove the door hinges (24) from the bracket
(20), remove hinge bolt (23), bushings (22), spacer

26) and nut (27).

5. Installation is in the reverse order of removal.

6. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

18, 10

23, 27

11, 30, 29

15 - 18 ft.lbs. (20 - 25 Nm)

18 - 22 ft.lbs. (25 - 30 Nm)

15 - 18 ft.lbs. (20 - 25 Nm)

Dash Support Removal

31

Front of Vehicle

31

5

6

4

3

2

1

20

24

30

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 13mm.............................................................. 1

Socket, 17mm.............................................................. 1

Wrench,13mm ............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (10) and nuts (11) that secure the A-pillar cap bracket (16) to the frame (Ref. Fig. 2).

2. Remove the bolt (18) and nut (19) that secure the A­pillar cap bracket (16) to the top of the door hinge
bracket (20). Remove the A-pillar cap bracket.

3. Remove the bolts (29) and nuts (30) that secure the door hinge bracket to the frame. Remove the door hinge bracket.

22

27

Fig. 2 Door Hinge and Bracket

26

Fig. 3 Dash Support and Hand Hold

Tool List Qty.

Ratchet.........................................................................1

Socket, 13mm..............................................................1

Socket, 17mm..............................................................1

Wrench,13mm..............................................................1

Wrench, 17mm.............................................................1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (31) that secure the outer legs of the dash support (5) to each side of the frame (1) (Ref. Fig. 3).

32

Repair and Service Manual

668061

FRAME

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

2. Remove bolts (6) that secure the inner legs of the support to the frame.

3. Remove the dash support from the frame.

4. Installation is in the reverse order of removal.

5. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

6

31

15 - 18 ft.lbs. (20 - 24 Nm)

15 - 18 ft.lbs. (20 - 24 Nm)

Hand Hold Removal

1. Release and remove the pins (4) that secure the handhold (2) into the dash support. (See Fig. 3)

2. Pull the hand hold out of the dash support tubes.

3. Installation is the reverse order of removal.

Front Shock Tower Brace Removal

8

1. Remove the bolts (8) that secure the front shock tower brace (7) to the frame (1) (Ref. Fig. 4). Remove the brace.

2. Installation is in the reverse order of removal.

3. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

8

15 - 18 ft.lbs. (20 - 24 Nm)

Rear Shock Tower Brace Removal

FOR VEHICLES

1

Front of Vehicle

MANUFACTURED
BEFORE MARCH 13, 2017

38

32

B

78

Fig. 4 Shock Tower Brace

Tool List Qty.

Ratchet........................................................................ 1

Socket, 13mm ............................................................. 1

Socket, 17mm ............................................................. 1

Wrench,13mm ............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs. ................................................ 1

Front of Vehicle

1

38

38

1

32

FOR VEHICLES
MANUFACTURED
AFTER MARCH 13, 2017

Front of Vehicle

Fig. 5 Rear Shock Tower Brace

668061

Repair and Service Manual

33

FRAME

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 17mm.............................................................. 1

B

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (38) that secure the rear shock tower brace (32) to the frame (1) (Ref. Fig. 5). Remove the brace.

33

Front of Vehicle

41

34

2. Installation is in the reverse order of removal.

3. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

38

30

15 - 18 ft.lbs. (20 - 24 Nm)

32

10

40

28

1

B-Pillar

31

42

27

Chassis Frame

34

Fig. 6 Seat Frame and B-Pillar Crossmember

Repair and Service Manual

668061

FRAME

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Seat Frame Removal

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 13mm.............................................................. 1

Socket, 17mm.............................................................. 1

Wrench,13mm ............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (41) and nuts (42) that secure the seat frame supports (40) to the seat frame(1) (See Fig. 6).

2. Remove the bolts (30) and nuts (31) that secure the seat frame (1) to the B-pillar crossmember (32).

3. Remove the bolts (27) and nuts (28) that secure the seat frame (1) to the B-pillars on each side of the vehicle frame.

4. Remove the bolts (10) that secure the legs of the seat frame (1) to the vehicle frame. Remove the seat frame from the vehicle.

5. Installation is in the reverse order of removal.

6. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

30, 31

33, 34

30 - 33 ft.lbs. (40 - 45 Nm)

30 - 33 ft.lbs. (40 - 45 Nm)

B

ITEM NO TORQUE SPECIFICATION

10

27, 28

30, 31

41, 42

15 - 16 ft.lbs. (20 - 22 Nm)

30 - 33 ft.lbs. (40 - 45 Nm)

30 - 33 ft.lbs. (40 - 45 Nm)

15 - 16 ft.lbs. (20 - 22 Nm)

B-Pillar Crossmember Removal

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 13mm.............................................................. 1

Socket, 17mm.............................................................. 1

Wrench,13mm ............................................................. 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove the bolts (30) and nuts (31) that secure seat
frame (1) to the B-pillar crossmember (32) (Ref. Fig.

6).

2. Remove the bolts (33) and nuts (34) that secure the
ends of the crossmember (32) to the top of the B-pil­lars of the vehicle frame. Remove the crossmember.

3. Installation is in the reverse order of removal.

4. Tighten hardware to the torque specified below:

668061

Repair and Service Manual

35

FRAME

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

36

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ROLLOVER PROTECTION SYSTEM (ROPS)

8

6

7

2

9

12

5

Front of Vehicle

4

8

8

B-Pillar

1

8

11

8

10

A-Pillar

C-Pillar

8

11

8

668061

Fig. 1 ROPS Components

Repair and Service Manual

37

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

The ROPS hardware and compo­nents must be assembled properly
and all hardware tightened to the

torques specified for the ROPS to provide occupant

B

protection during a rollover.

Do not drill holes in the ROPS components or mod­ify the ROPS in any way.

Removing the ROPS as a Complete Unit

Tool List Qty.

Socket, 15mm.............................................................. 1

Ratchet ........................................................................ 1

Wrench, 15mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Disconnect CHMSL (Center High Mounted Stop
Light) wire connection at the bottom of the passen­gers side C-pillar.

2. Remove the bolts (8) and the nuts (9) that secure the ROPS side tubes (1 and 2) to the seat back supports (24) (Ref. Fig. 1).

3. Remove the bolts (8) and the mounting plate (10)
that secure the front of the ROPS side tubes (1 and

2) to the A-pillar of the frame.

4. Remove the bolts (8) and the mounting plate (11)
that secure the rear of the ROPS side tubes (1 and

2) to the B-pillar of the frame.

5. Remove the bolts (8) and the mounting plate (11) that secure the extended cab tubes (4 and 6) to the C-pillar of the frame.

6. With the aid of an assistant, lift the ROPS off the vehicle.

7. Installation is the reverse order of removal.

NOTICE: Loosen all ROPS hardware before installa­tion to allow the mounting holes to align properly.

8. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

8

37 - 41 ft.lbs. (50 - 55 Nm)

INSTALLING ROPS COMPONENTS

NOTICE: Loosen all ROPS hardware before installa­tion to allow the mounting holes to align properly.

1. Remove the cargo tray and cab closeout panel. See the BODY section.

2. Position the driver side ROPS tube (1) as shown (Ref. Fig. 1). Secure the front of the side ROPS tube (1) to the vehicle frame A-pillar with bolts (8) and mounting plate (10). Finger tighten hardware to allow for adjustment.

3. Attach the other end of the driver side ROPS tube (1) to the B-pillar. Secure with bolts (8) and mounting bracket (11). Finger tighten hardware to allow for adjustment.

4. Repeat the above steps for installing the passenger side ROPS tube (2).

B. ROPS Extended Cab Tubes Installation

Tool List Qty.

Socket, 15mm..............................................................1

Ratchet.........................................................................1

Wrench, 15mm.............................................................1

Front of Vehicle

4

9

9

12

Fig. 2

1. Position the lower end of the extended cab ROPS
tube (4) over the driver side C-pillar of the vehicle
frame and secure with bolts (8) and nuts (9) (Ref.
Fig. 1). Finger tighten hardware to allow for adjust­ment.

2. Repeat the above steps for installing the passenger side extended cab ROPS tube (6).

3. Do not install the top bracket hardware of the extended cab ROPS tube (4 and 6) until the rear cross-tube (12) has been installed (Ref. Fig. 2).

8

7

A. ROPS Side Tube Installation

Tool List Qty.

Socket, 15mm.............................................................. 1

Ratchet ........................................................................ 1

Wrench, 15mm ............................................................ 1

38

Repair and Service Manual

C. Rear Cross-tube Installation

Tool List Qty.

Socket, 15mm..............................................................1

Ratchet.........................................................................1

Wrench, 15mm.............................................................1

668061

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1. Slide the ends of the cross-tube (12) in between the
ROPS tube mounting brackets (1 and 4) and align
the mounting holes of all three brackets (Ref. Fig.

1)(Ref. Fig. 2). From the top, insert bolts (8) into the
mounting holes, and secure with lock nuts (9). Finger
tighten bolts to allow for adjustment.

2. Repeat the above steps to secure the other end of the rear cross-tube to the driver side ROPS tubes (2 and 6).

D. CHMSL and Extended Cab Cross-tube

Tool List Qty.

Socket, 15mm ............................................................. 1

Socket, Phillips Head Bit, #2 ....................................... 1

Ratchet........................................................................ 1

Wrench, 15mm ............................................................ 1

Wrench, 8mm .............................................................. 1

Torque Wrench, ft. lbs. ................................................ 1

Front of Vehicle

14

7

10

wiring harness of the cross-tube. Align the mounting
holes of the CHMSL (10) and the mounting bracket.
Insert screws (12) from the front face of the CHMSL.
Secure with lock nuts (14).

2. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

12

3. Connect the CHMSL wiring harness to the exposed main harness coming from the extended cab ROPS tube (7).

4. Align the mounting holes on the CHMSL back cover (11) with the mounting bracket holes and secure with removable rivets (13) (Ref. Fig. 4).

2 - 3 ft.lbs. (3 - 4 Nm)

11

B

A

Existing
Mounting Bracket

VIEW “A” FROM REAR

7

A

Fig. 3 CHMSL

1. Mount the Center High Mount Stop Light (CHMSL)
(10) to the existing mounting bracket on the center of
the extended cab cross-tube (7) (Ref. Fig. 3). Make
sure the wiring is on the same side as the exposed

CHMSL

CHMSL
Harness

Harness

Connector

Connector

Main Harness
Connector

12

13

Front of Vehicle

Fig. 4 CHMSL Back Cover

5. Position the extended cab cross-tube (7) as shown.
Route the end of the wiring harness down through
the top hole in the passenger side extended cab
ROPS tube (4) and down through the vertical ROPS
tube (Ref. Fig. 5). Connect the CHMSL harness to
the rear harness as shown. Use a cable tie to secure
any excess wiring to the vehicle frame.

Front of Vehicle

Route wiring
through top
ROPS hole

7

4

Fig. 5 CHMSL Wiring

668061

Repair and Service Manual

39

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

6. Once the wiring has been inserted into the extended
cab ROPS tube, align the mounting bracket holes of
the extended cab cross-tube (7) to the corresponding

B

mounting bracket of the extended cab ROPS tube
(4). Secure with bolts (8) and lock nuts (9). Finger
tighten bolts to allow for adjustment.

7. Repeat the above step to secure the extended cab cross-tube to the driver side extended cab ROPS tube.

23

E. Front Cross-tube Installation

Tool List Qty.

Socket, 15mm.............................................................. 1

Ratchet ........................................................................ 1

Wrench, 15mm ............................................................ 1

1. Position the cross-tube (5) onto the top mounting brackets of the driver and passenger side ROPS tubes (Ref. Fig. 6).

2. Align the holes of both mounting brackets and secure with bolts (8) and lock nuts (9). Finger tighten bolts to allow for adjustment.

8

9

Front of Vehicle

Fig. 6 Front Cross-tube

2

5

F. Seat Back Support Installation

Tool List Qty.

Socket, 15mm.............................................................. 1

Ratchet ........................................................................ 1

Wrench, 15mm ............................................................ 1

1. Position the passenger side seat back support (24) as shown (Ref. Fig. 7). Align the top mounting holes on the support (24) with the mounting bracket, and secure with bolts (23) and nuts (26). Finger tighten hardware to allow for adjustment.

26

8

24

Front of Vehicle

9

Fig. 7 Seat Back Support

2. Secure the bottom of the seat back support (24) to the vehicle frame with bolts (8) and nuts (9).

3. Finger tighten hardware to allow for adjustment.

4. Repeat the above steps for the installation of the driver side seat back support.

G. Tighten ROPS Hardware

Tool List Qty.

Socket, 15mm..............................................................1

Ratchet.........................................................................1

Wrench, 15mm.............................................................1

Torque Wrench, ft. lbs..................................................1

5. After all the ROPS components are installed, tighten
hardware to the torque specified below in the follow­ing order (see previous figures for reference):

ITEM NO TORQUE SPECIFICATION

40

8

Repair and Service Manual

37 - 41 ft.lbs. (50 - 55 Nm)

668061

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

a. Tighten the seat back support (24, 25) to ROPS

tubes (2, 1) and the vehicle frame.

b. Tighten the ROPS tubes (1, 2) and extended cab

ROPS tubes (3, 4) to the vehicle frame.

c. Tighten the front cross-tube (5), rear cross-tube

(6), and extended cab cross-tube (7) to the side
ROPS tubes (1 - 4).

Front of Vehicle

B

SEATBELT INSTALLATION

Tool List Qty.

Socket, 7/16” ............................................................... 1

Ratchet........................................................................ 1

Wrench, 7/16”.............................................................. 1

Torque Wrench, ft. lbs. ................................................ 1

1. Attach the top of the seatbelt to the mounting bracket
at the top of the ROPS tube (2) with bolt (16) from
the front to back (Ref. Fig. 8). Secure with lock nut
(15). Guide the belt down to prevent twisting the belt.
Make sure the flat side of the seatbelt retractor is
flush against the bracket toward the front of the vehi­cle.

2. Attach the seatbelt retractor to the bracket at the bot­tom of the ROPS tube (2) (Ref. Fig. 9).

3. Insert the tab on the back of the seatbelt retractor
through the corresponding hole in the bracket to pre­vent the retractor from rotating.

4. Secure the seatbelt retractor to the bracket by insert­ing bolt (18) through the mounting hole in the retrac­tor and through the ROPS tube (2). Secure the bolt
with lock nut (19).

5. Secure the bottom of the seat belts to the seat frame with bolts (27) and nuts (28) (Ref. Fig. 10).

6. Secure the seat belt latches (5) to the center of the seat frame with bolts (8) and nuts (9).

7. Tighten hardware to the torque specified below:

ITEM NO TORQUE SPECIFICATION

16

Seatbelt
Retractor

18

Mounting
Bracket

15

2

Fig. 8 Seat Belt

2

19

Front of Vehicle

18, 19 48 - 52 ft.lbs. (65 - 71 Nm)

15, 16 48 - 52 ft.lbs. (65 - 71 Nm)

27, 28

8, 9

668061

44 - 55 ft.lbs. (60 - 75 Nm)

48 - 52 ft.lbs. (65 - 71 Nm)

Repair and Service Manual

Fig. 9 Seat Belt Retractor

41

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

Fig. 10 Seat Belt Latches

Headrest Installation

9

Front of Vehicle

5

28

Seat Frame

8

27

27

Front of Vehicle

Fig. 11 Headrest

1. Attach the headrest (27) to the top of the seat back support by pushing it in against the support and then sliding down to lock into place (Ref. Fig. 11).

2. Secure the headrest to the seat back support with ratchet rivets (29).

29

42

Repair and Service Manual

668061

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

668061

Repair and Service Manual

43

ROLLOVER PROTECTION SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

44

Repair and Service Manual

668061

TRUCK BED

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TRUCK BED

Front of Vehicle

Bed Stop
Bracket

Gas
Spring

Bed Frame

Clevis Pin

Cotter Pin

Frame

Bushing

668061

Bed Frame Components

Repair and Service Manual

45

TRUCK BED

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TRUCK BED REMOVAL

Tool List Quantity

B

Back Brace .................................................................. 2

Ratchet ........................................................................ 1

Socket, 10mm.............................................................. 1

The truck bed is heavy and difficult
to handle. To prevent possible per-

sonal injury, it is strongly recom­mended that an assistant or adequate lifting device
be used to remove the truck bed from the vehicle.

Bed Stop Bracket

BoltBolt

Fig. 1 Truck Bed

To safely remove the bed from the vehicle, first relieve the
pressure from the gas spring as described below:

1. With the bed in the down position, remove the two

bolts that secure the bed stop bracket to the bed
frame. Remove the bracket.

2. Release the bed latch and lift the truck bed until the

gas spring is fully extended.

3. With a person on each side of bed, remove cotter pin

and clevis pin that connects the gas spring to truck
bed and swing the gas spring down to rest on the
frame

4. Lower the truck bed.

5. Remove cotter pins and clevis pins from the truck

bed pivots.

6. Remove bed from the vehicle.

7. Install the truck bed in the reverse order of disassem-

bly.

NOTICE: Make sure the pivot bushings are in place
before installing the bed.

Make sure the heat shields are attached before
installation.

Gas Spring Connection
to Underside of
Truck Bed

Heat Shield

Clevis Pins and
Cotter Pins

Fig. 2 Truck Bed Removal

46

Repair and Service Manual

668061

TRUCK BED

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Decal Replacement

Tool List Qty.

Alcohol..................................................................... A/R

Clean Cloth.................................................................. 1

Squeegee.................................................................... 1

When replacing decals on the body panels:

1. Prepare the surface by cleaning with alcohol and a clean cloth. Allow the surface to dry.

2. Peel away the decal backing and apply to the sur­face.

3. Use a squeegee to smooth out the decal and remove
any air pockets trapped under the decal. A needle
can be used to puncture any remaining air pockets
that cannot be otherwise removed.

B

668061

Repair and Service Manual

47

TRUCK BED

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

48

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

WEATHER PROTECTION

GENERAL

The canopy does not provide pro­tection from falling objects.

The windshield does not provide protection from
tree limbs or flying objects.

The canopy and windshield are designed for weather
protection only.

Clean with water and a clean cloth. Minor scratches can
be removed with a commercial plastic polish or Plexus
plastic cleaner available from the service parts depart­ment.

CANOPY

Tool List Qty.

Deep Well Socket, 15 mm ...........................................1

Wrench, 15 mm ...........................................................1

Torx Bit, T27.................................................................1

Socket Extension.........................................................1

Hex Bit, 6 mm ..............................................................1

Torque Wrench, ft. lbs..................................................1

Ratchet ........................................................................1

3. Finger tighten the hardware to allow for adjustment.

4. Repeat the above step to install the other three mounting brackets (4, 6, 7) to the corresponding ROPS brackets on the front driver side, rear driver side, and rear passenger side ROPS brackets.

Installing Mounting Brackets

Loosen existing
hardware to
allow room for
canopy bracket.

5

Front of Vehicle

Fig. 1

1. Loosen the ROPS (Roll Over Protection System) hardware at each of the four upper corner brackets (Ref. Fig. 1). Do not remove the bolts completely.

2. Slide the passenger side front canopy mounting bracket (5) underneath the bolt heads at the front passenger side of the ROPS.

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Repair and Service Manual

49

WEATHER PROTECTION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Installing Canopy Clamps

B

6

7

3

1. Place canopy clamps (3), with the hinged side facing out, onto each side ROPS tube (Ref. Fig. 2).

2. Close the hinges around the ROPS tubes and secure with Torx bolts (11) and washers (12) (Ref. Fig. 3).

3. Finger tighten hardware to allow for adjustment.

11

4

3

5

Front of Vehicle

Fig. 2

3

Front of Vehicle

Fig. 3

12

50

Repair and Service Manual

668061

WEATHER PROTECTION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Installing the Canopy

4

13

3

9

10

B

Front of Vehicle

Fig. 4 Canopy

1. Align the mounting holes on the canopy with the holes in the mounting brackets (4-7) and canopy clamps (3) (Ref. Fig. 2) (Ref. Fig. 4).

2. Slide the canopy clamps (3) along the ROPS tube so they are aligned with the canopy mounting holes.

3. When the canopy clamps are aligned with the can­opy mounting holes, tighten the canopy clamp bolts
(11) to 7 - 9 ft. lbs. (10 - 12 N-m) torque.

4. Secure the canopy to the clamps and brackets with Torx bolts (10), washer (13), rubber washer (14) and lock nuts (9).

5. Finger tighten hardware to allow for adjustment. After all hardware has been installed, tighten to a torque of 13 - 15 ft. lbs. (17 - 20 N-m).

6. Tighten all ROPS hardware to 30 - 33 ft. lbs. (40 - 45 N-m) torque.

7. Removal of the canopy is in the reverse order of installation.

14

6

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51

WEATHER PROTECTION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

52

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

WHEELS AND TIRES

Lug Nut

Dust Cap

(Style of wheel and tire may differ from shown.)

Valve stem must always be
to the outside of the wheel.

Always replace the dust cap.

Fig. 1 Wheels and Tires

WHEEL AND TIRE SERVICE

To prevent injury caused by a bro­ken socket, use only sockets
designed for impact wrench use.

Never use a conventional socket.

Follow the tire maintenance procedures as instructed in
this manual and on the labels on the vehicle.

Always use approved size and type of replacement tires.
See GENERAL SPECIFICATIONS on page 161.

Worn, improperly inflated, improper
sized, or incorrectly installed tires

will affect vehicle handling and could cause an
accident resulting in severe injury or death.

To decrease the risk of tire explosion, do not
exceed the tire inflation rating on the tire sidewall.
Make sure the tires are properly inflated at all times
of operation. See GENERAL SPECIFICATIONS on
page 161.

Inflate all tires to the same pressure. Operating with
unequal or incorrect pressure can adversely affect
steering and handling and could cause an accident
resulting in severe injury or death.

668061

Repair and Service Manual

53

WHEELS AND TIRES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Tire Tread Depth

Replace the tires
when the tread depth

B

is worn to 3.5 mm or
less.

Not less than 3.5 mm

Tire Repair

Use a tire plug to repair small holes in the tread part of the
tire. For large holes or holes/cuts in the tire sidewall, the
tire must be replaced.

1. Remove the wheel from the vehicle.

2. Locate the leak in the tire.

a. If the tire is very low or flat, fully inflate the tire.

b. Brush soapy water over the surface of the tire.

Air bubbles will be visible where the air is leaking
from the tire.

c. Mark the hole with chalk.

4. Install the plug according to the manufacturer’s instructions.

5. Install the wheel on the vehicle.

6. Fully inflate the tire. See GENERAL SPECIFICA­TIONS on page 161.

NOTICE: Tire plug tools and plugs are available at
automotive outlets. The tire does not have to be
removed from the wheel to install the tire plug.

Wheel Installation

Do not tighten lug nuts to more than
100 ft. lbs. (135 Nm) torque.

NOTICE: It is important to follow the ‘cross
sequence’ pattern when installing lug nuts. This will
assure even seating of the wheel against the hub.

The STAMPEDE 900 rear tires are wider than the
front tires. Make sure you reinstall the wheels in
their correct position.

1. With the valve stem to the outside, mount the wheel
onto the hub with lug nuts. Be sure to position the
wheel on hub correctly (uni-directional tires require
the arrow indicating direction of rotation to be point­ing forward when moving forward).

2. Finger tighten lug nuts in a cross sequence pattern (Ref. Fig. 2).

Lug Nut Tightening Pattern

Tire Replacement

Tire replacement requires a tire mounting machine and
must be done by a qualified tire center or TEXTRON OFF
ROAD dealer.

Wheel Removal

Tools List Qty.

Lug Wrench, 19mm ..................................................... 1

Impact Wrench ............................................................1

Impact Socket, 19mm..................................................1

Torque Wrench, ft. lbs..................................................1

1. Lift the vehicle.

2. Remove the lug nuts.

3. Remove the wheel from the hub.

Fig. 2

3. Then, tighten lug nuts to torque values in 20ft. lbs. (27 Nm) increments following the same cross sequence pattern.

ITEM TORQUE SPECIFICATION

Lug Nut 85 - 100 ft. lbs. (115 - 135 Nm)

54

Repair and Service Manual

668061

WHEELS AND TIRES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

668061

Repair and Service Manual

55

WHEELS AND TIRES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

56

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BRAKES

11

Brake Caliper

14

11

3

11

9

3

14

3

Brake Caliper

4

Part of Frame

12

1

2

8

Front of Vehicle

5

11

Frame and suspension partially shown for clarity

*

11

Brake Caliper

14

Brake Caliper

11

14

2

2

Fig. 1 Brake System

668061

Repair and Service Manual

57

BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MAINTENANCE

Daily Brake Performance Test

B

NOTICE: To ensure correct braking performance, all
periodic maintenance, inspections and procedures
must be performed. See SCHEDULED MAINTE­NANCE CHART on page 166. A Daily Brake Perfor­mance Test must be performed, and the entire brake
system must be serviced in accordance with the
SCHEDULED MAINTENANCE CHART.

The brake system must be bled whenever any part
of the brake system has been replaced.

The STAMPEDE 900 has front and rear hydraulic disc
brakes. Perform scheduled maintenance on the brake
system at the intervals indicated in the Scheduled Mainte­nance Chart.

Check the brake fluid level before each operation. Test
the brakes for function before each use.

Press the brake pedal. The pedal should have some ini­tial free play, and then become resistant. This indicates
proper performance.

If the brake pedal has a soft feel or loses resistance, per­form a brake system inspection.

Brake System Inspection

1. Check brake fluid level.

2. Check the brake system for fluid leaks.

3. Check the brake pedal for excessive travel or a spongy feel.

4. Check the brake calipers for looseness.

5. Check the brake pads for wear or damage. Replace the brake pads if worn to 3/64 inch (1 mm) or less (Ref. Fig. 2).

Never apply WD-40 or any petro­leum product to the brake discs.

These products are flammable and
can also reduce the friction between the brake pad
and caliper and increase the possibility of an acci­dent that can result in severe injury or death.

Do not allow brake fluid to contact the brake pads. If
the brake pads become wet with hydraulic fluid,
wipe the brake pads and rotor until they are dry.

Complete brake failure usually indicates a loss of hydrau­lic fluid pressure.

If the brake pedal has a soft feel, bleed the brakes to
remove air from the brake system.

A brake pedal that loses resistance indicates a leak in the
hydraulic system:

1. Check brake fluid level. If the fluid is low, inspect the

system for leaks.

a. Check for leaks by applying pressure to the

pedal gradually and steadily.

b. If pedal sinks very slowly to the floor, the system

has a leak along the brake lines or at the hydrau­lic cylinder. If no external leaks are apparent, the
problem is likely inside the master cylinder.

3. If leaks are found, repair the leaks in the brake sys-

tem, or repair or replace the master cylinder.

4. Bleed the brakes to remove air from the brake sys-

tem.

NOTICE: Do not allow brake fluid to contact painted
surfaces.

Brake Fluid

When adding or changing brake

fluid, always use brake fluid from an

unopened bottle. After opening a
bottle of brake fluid, always discard the unused por­tion. Do not store, or use from an opened bottle.
Brake fluid rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the
brake fluid to drop. This can lead to premature brake
fade and the possibility of an accident that can
result in severe injury or death.

3/64 inch
(1 mm)

Fig. 2 Check Brake Pad Wear

6. Check the brake rotors for cracks, corrosion, warping or other damage.

7. Clean any grease found on the brake discs with an approved brake cleaner or alcohol.

58

Repair and Service Manual

The brake fluid reservoir is located under the cowl near
the driver side front wheel. Remove the panel from the
cowl to access the reservoir.

668061

BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

hone. If corrosion or deposits are detected on the master
cylinder, replace it with a new one.

Fig. 3 Check Brake Fluid Level

In addition to the scheduled maintenance interval for
changing the brake fluid, the brake fluid must also be
changed in the following conditions:

• the fluid becomes contaminated

• the fluid level falls BELOW the MIN mark

• the type and brand of the fluid in the reservoir are
unknown

1. Park the vehicle on a level surface.

2. Check the brake fluid level in the reservoir (Ref. Fig.

3). The fluid level should be between the upper MAX
and lower MIN lines.

3. If the level is below the upper MAX line, add brake fluid:

a. Clean any dirt and debris from around the reser-

voir cap and remove the cap.

b. Add brake fluid until it reaches the upper MAX

line.

c. Reinstall the cap.

d. Clean any spilled brake fluid from the area.

e. Dispose of the unused portion of the brake fluid.

6. Press and hold the brake pedal fully down for a few seconds.

7. Check for fluid leakage around the fittings.

Master Cylinder Replacement

12

1

3

11

9

2

4

Tool List Qty.

Drain Pan.....................................................................1

Shop Cloths .............................................................A/R

Needle Nose Pliers ......................................................1

Wrench, 13mm ............................................................2

Wrench, 14mm ............................................................1

Ratchet ........................................................................1

Socket, 13mm..............................................................1

Socket, 14mm..............................................................1

Torque Wrench, ft. lbs..................................................1

NOTICE: When replacing the master cylinder, it is
likely that brake fluid will leak from the master cylin­der. Do not allow brake fluid to contact the painted
body components of the vehicle. Clean off immedi­ately if contact is made.

Part of Frame

Fig. 4 Master Cylinder

DO NOT reuse crush (11) washers
(Ref. Fig. 4).

8

5

11

B

MASTER CYLINDER

The master cylinder is mounted to the frame, under the
cowl on the driver side of the vehicle. The master cylinder
will eventually require replacement due to deterioration of
the cylinder seals (cups). Fluid will leak past the cups and
show as an external leak. A common symptom is a soft
brake pedal, meaning that it goes all the way to the floor.
The rubber parts wear with use, or deteriorate with age or
fluid contamination. Corrosion or deposits formed in the
cylinder bore, due to moisture or dirt in the hydraulic sys­tem may cause wear of the cylinder bore or related parts.
Do not try to remove corrosion or deposits with a cylinder

668061

Repair and Service Manual

1. Turn the key to the OFF position, and remove it from the switch.

2. Place a drain pan under the master cylinder (1) (Ref. Fig. 4).

3. Clean the area around the master cylinder to prevent dirt and grease from contaminating the hydraulic system.

4. Disconnect the front brake lines (2) from the master cylinder (1) by removing banjo bolt (8) and washers (11).

5. Disconnect the rear brake lines (3) by unplugging and removing the brake pressure switch (9).

59

BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

6. Remove the cotter pin and clevis pin from the brake pedal.

7. Remove two hex head bolts (4) and nuts (5) that

B

secure the master cylinder and shield (12) to the
frame. Remove the master cylinder and shield from
the vehicle.

8. Installation of master cylinder is the reverse of
removal.

9. Tighten hardware to the torque values specified below:

Item Torque Specification

15

18

16

4, 5

8

9

10. Fill the master cylinder with DOT 4 brake fluid and bleed the brake system.

11. After bleeding the brake system, check for leaks along all lines and at the master cylinder.

24 - 26 ft.lbs. (32 - 35 Nm)

20 - 22 ft.lbs. (27 - 30 Nm)

20 - 22 ft.lbs. (27 - 30 Nm)

Brake Pad Replacement

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 14mm.............................................................. 1

Socket, 12mm.............................................................. 1

Wrench, 14mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

Replace brake pads as a full set on both front and rear
wheels. To remove the brake pads, lift and support the
vehicle as instructed in the SAFETY section.

1. Remove the wheel. See Wheel Removal on page 54.

2. Remove the two bolts (15) and lock washers (16) that secure the caliper assembly (17) to the spindle (18) (Ref. Fig. 5). Swing the caliper free from the spindle and the rotor.

17

30

Fig. 5 Brake Caliper Removal

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Repair and Service Manual

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BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

3. Remove the two bolts (19) securing the outer caliper half (20) to the inner caliper half (Ref. Fig. 6).

20

19

21

4. Remove the outer caliper half (21). Slide the brake pads (22) off the slide pins (23).

5. Install the new brake pads (22) onto the slide pins (23).

6. Install the outer caliper half (20) onto the inner cali­per half (21) and secure with two bolts (19) finger
tight.

7. Separate the brake pads (22) and place the caliper assembly (17) onto the rotor.

8. Align the mounting holes on the caliper assembly
with the corresponding holes on the spindle. Secure
with two bolts (15) and nuts (16).Tighten the hard­ware to the torques specified below.

Item Torque Specification

B

23

22

15

19

30

9. Replace the wheel. See Wheel Installation on page 54.

30 - 35 ft.lbs. (40 - 48 Nm)

27 - 33 ft.lbs. (37 - 45 Nm)

9 - 11 ft.lbs. (12 - 15 Nm)

Rotor Replacement

Tool List Qty.

Ratchet ........................................................................1

Socket, 13mm..............................................................1

Torque Wrench, ft. lbs..................................................1

NOTICE: Do not turn the rotor (disc brake hub) to
remove grooves or high spots.

668061

Fig. 6 Brake Pad Replacement

If the rotor (disc) has deep grooves or gouges, it must be
replaced. If the pad contact area has worn the rotor to a
thickness less than.200” +/ -.005”, the rotor must be
replaced.

Repair and Service Manual

Fig. 7 Rotor Replacement

61

BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

If the rotor needs replacement, the caliper and pads must
be moved to access the rotor. See Brake Pad Replace-
ment.

B

1. To remove the rotor, lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Remove the wheel. See Wheel Removal on page 54.

3. Remove the hub from the axle. See Front Hub Removal on page 68.

4. Remove the four bolts that secure the rotor to the hub. Remove the rotor (Ref. Fig. 7).

5. Installation is the reverse order of removal.

6. Tighten the rotor bolts in a cross sequence to the torque specified below:

.

Item Torque Specification

Rotor Bolts

22 - 26 ft. lbs. (30 - 35 Nm)

BLEEDING AND FLUSHING

Tool List Qty.

Shop Towels ............................................................ A/R

Hose ........................................................................ A/R

Clean Container........................................................... 1

Brake Fluid, DOT 4..................................................A/R

Wrench, 1/4” Box End .................................................1

Crowfoot Wrench, 1/4”................................................. 1

Torque Wrench, in. lbs................................................. 1

Socket, 1/4” .................................................................1

Bleeding Sequence

Bleeder
Valve

Bleeder
Hose

Brake
Caliper

Figure 8 Bleeder Valve

Bleed at each caliper in the following succession:

1. Passenger side rear wheel

2. Driver side rear wheel

3. Passenger side front wheel

4. Driver side front wheel caliper.

Never use excess brake fluid or
return it to the original container.
Dispose of brake fluid properly.

Bleeding

The brake hydraulic system must be free of air to function
properly.

The brake pedal and master cylinder acts as a hydraulic
pump to remove air and brake fluid from the system.

Bleed the hydraulic system at all wheels if:

• The primary brake line was disconnected from the
flexible brake hose.

• Air was introduced into the system through low fluid
level in master cylinder reservoir.

If a line or hose was disconnected at any fitting located
between the master cylinder and calipers, all wheel cali­pers served by the disconnected line or hose must be
bled.

NOTICE: An assistant is necessary to perform this
procedure.

Use a clean cloth to clean the master cylinder reservoir
and caliper bleeder valves. Clean each fitting before
opening to prevent contamination of the system.

Fill the master cylinder reservoir to MAX line with new
brake fluid before starting, and after bleeding is complete.

Check the master cylinder fluid level frequently during
bleeding and keep the reservoirs at least half full.

The following steps apply to one bleeder valve. Repeat at
the bleeder valve of each wheel.

1. Attach a bleeder hose to the bleeder valve (Ref. Fig­ure 8). Put the other end of the hose in a glass con­tainer partially filled with brake fluid.

NOTICE: Be sure that the free end of the hose is
submerged in brake fluid. This shows air bubbles as
they come out of the system, and prevents air from
being sucked into the system through the bleeder
screw.

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Repair and Service Manual

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BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

2. Apply moderate (40 - 50 lbs. [18 - 23 kg]), steady pressure on the brake pedal, and open the bleeder valve.

Do not force the brake pedal to the
floor. The operating rod can be
forced into the master cylinder

where it can damage internal components.

3. If the brake pedal goes to the floorboard without removing all of the air bubbles, close the bleeder valve and release the brake pedal slowly. Repeat steps 1 and 2.

NOTICE: The bleeder valve at the brake caliper must
be closed at the end of each stroke, and before the
brake pedal is released to ensure that air cannot
enter the system. It is also important that the brake
pedal be returned to the full released position.

4. When fluid coming from the submerged end of the hose is clear and free of bubbles, close the bleeder valve and release the brake pedal. Tighten the bleeder valve to the maximum torque value specified below.

.

Item Torque Specification

BRAKE AND ACCELERATOR PEDALS

Brake Pedal Removal And Installation

Tool List Qty.

Needle Nose Pliers ......................................................1

Socket, 9/16”................................................................1

Ratchet ........................................................................1

Wrench, 3/4” ................................................................1

Torque Wrench, ft. lbs..................................................1

1. Disconnect the brake pedal from the master cylinder push-rod by removing cotter pin (9) and clevis pin (10) from the brake pedal (Ref. Fig. 9).

10

9

B

Bleeder Valve 38 in. lbs. (4 Nm)

Flushing the Brake System

The process of removing old brake fluid to remove water,
mineral oil or other contaminants from the system is
called flushing the hydraulic system.

Flushing is similar to bleeding except that a greater
amount of brake fluid is discharged from each bleeder
point to make sure that all of the dirty or contaminated
fluid is removed.

Fig. 9 Disconnect Brake Pedal

2. Remove pivot bolt (6), bushings (11) and lock nut (7) (Ref. Figure 10).

3. Remove pedal.

4. Brake pedal installation is the reverse order of removal.

5. Tighten bolt (6) and nut (5) to the torque specified below.

Item Torque Specification

6, 7 18 - 22 ft. lbs. (24 - 30 Nm)

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BRAKES

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B

10

15

7

6

11

9

2

Chassis
Frame

Front

of

Vehicle

Accelerator
Pedal

Front of Vehicle

Figure 10 Brake Pedal Removal

Accelerator Pedal Removal

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 10mm.............................................................. 1

Wrench, 10mm ............................................................ 1

1. Disconnect the accelerator wire from the harness.

2. From under the vehicle, remove the two bolts that secure the accelerator pedal to the vehicle frame (Ref. Figure 11).

3. Remove the pedal.

4. Installation is the reverse of removal.

5. Tighten nuts to the torque specified below.

Item Torque Specification

15 9 - 10 ft. lbs. (12 - 14 Nm)

Figure 11 Accelerator Pedal

64

Repair and Service Manual

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BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

668061

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65

BRAKES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

66

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FRONT CV SHAFT, SUSPENSION AND STEERING

32

16

32

28

Front of Vehicle

38

37

28

17

28

21

21

45

22

27

27

33

31

37

33

31

37

28

33

46

11

46

12

39

33

668061

28

22

5

6

Fig. 1 Front Suspension Components

Repair and Service Manual

30

24

23

40

67

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FRONT SUSPENSION

NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise

B

specified. If torque values are not specified, refer to
the Torque Specifications table. See TORQUE
SPECIFICATIONS on page ix.

To reduce the possibility of per­sonal injury, follow the lifting proce­dure. See LIFTING THE VEHICLE on

page 13.

Maintenance

See RECOMMENDED LUBRICANTS AND FLUIDS on
page 168.

Lubrication points can be found on the upper and lower
control arms. Use a maximum of three pumps of grease
per fitting.

Routine examination of the tires will indicate if a wheel
alignment is required.

The rod ends are sealed and do not require lubrication.
The steering unit is also sealed and requires no additional
lubrication.

Wheel Bearing Test

To check for worn wheel bearings, perform the following
procedure:

NOTICE: The axle nut must be installed at the
proper torque for the wheel bearing test to be accu­rate.

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Grasp the wheel at the top and bottom of the tire.

3. Apply firm back and forth pressure on the wheel. If any movement is noted, the wheel bearing must be pressed out of the spindle and replaced

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

4. At the center of the hub, remove the cotter pin (40),
axle nut (23) and washer (24) from the axle (Ref. Fig.

2)(Ref. Fig. 3).

40

Fig. 2 Remove Cotter Pin

Front Hub Removal

Tool List Qty.

Wheel Chocks .............................................................4

Floor Jack .................................................................... 1

Jack Stands ................................................................. 4

Plastic Hammer ........................................................... 1

Needle Nose Pliers......................................................1

Impact Wrench ............................................................1

Impact Socket, 27mm..................................................1

Torque Wrench, ft. lbs..................................................1

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Remove front wheel. See Wheel Removal on page 54.

68

Repair and Service Manual

24

23

Fig. 3 Remove Axle Nut and Washers

5. Tap the hub with a plastic hammer while applying outward pressure until the hub slides off the splines of the axle (Ref. Fig. 4).

668061

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

4. Remove the hub. See Front Hub Removal on page 68.

5. Remove the nut (2) that secures the spindle to the steering rack ball joint (3) (Ref. Fig. 5)(Ref. Fig. 6). Tap the spindle assembly with a hammer to separate it from the ball joint.

3

Fig. 4 Remove the Hub

6. The installation of the hub is the reverse of disas­sembly.

7. Clean the splines of the hub and axle and apply anti­seize before installation.

8. Tighten the hardware to the torque values specified below:

2

B

Item Torque Specification

23 181 - 199 ft. lbs. (245 - 270 Nm)

Front Spindle Removal

Tool List Qty.

Wheel Chocks ............................................................. 4

Floor Jack.................................................................... 1

Jack Stands................................................................. 4

Plastic Hammer ........................................................... 1

Needle Nose Pliers...................................................... 1

Ratchet........................................................................ 1

17mm Socket .............................................................. 1

19mm Socket .............................................................. 1

Wrench, 17mm ............................................................ 1

Wrench, 19mm ............................................................ 1

Impact Wrench ............................................................ 1

Impact Socket, 24mm.................................................. 1

Torque Wrench, ft. lbs. ................................................ 1

1. Lift and support vehicle. See LIFTING THE VEHI-
CLE on page 13.

2. Remove the front wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

Fig. 5

Rack Ball
Joint

668061

Repair and Service Manual

Fig. 6 Rack Ball Joint

69

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

30

31

Fig. 9 Spindle Nut and Cotter Pin

Fig. 7 Ball Joint Separation

Fig. 10 Remove Spindle Hardware

6. Remove the cotter pin (31) and castle nut (30) that
secure the spindle to the lower control arm (Ref. Fig.

10). Tap the spindle assembly downward with a
hammer to separate it from the ball joint.

7. Slide the spindle assembly off of the CV axle splines.

8. The installation of the spindle assembly is the reverse of disassembly.

9. Tighten the hardware to the torque values specified below:

Fig. 8 Tap Spindle with Hammer

Remove the cotter pin (31) and castle nut (30) that secure
the spindle to the upper control arm (Ref. Fig. 9). Tap the
spindle assembly downward with a hammer to separate it
from the ball joint (Ref. Fig. 8).

70

Repair and Service Manual

Item Torque Specification

2 17 - 20 ft. lbs. (23 - 27 Nm)

30 18 - 22 ft. lbs. (24 - 30 Nm)

668061

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FRONT AXLE

CV Shaft Replacement

Tool List Qty.

Pry Bar ........................................................................ 1

Drain Pan .................................................................... 1

Inspect the front axle (CV shaft) for
contamination, especially if there

are any torn CV boots around the
axle. Replace the front axle if any contamination is
found.

1. Lift and support vehicle. See LIFTING THE VEHI-

CLE on page 13.

2. Remove the front wheel. See Wheel Removal on

page 54.

3. Remove the brake calipers from the rotor. See Brake

Pad Replacement on page 60.

4. Remove the hub. Refer to See Front Hub Removal

on page 68.

5. Remove the front spindle assembly. See Front Spin-

dle Removal on page 69.

6. Remove the front axle from the differential using a

pry bar. Make sure that the hog ring is in place on the
CV shaft splines (Ref. Fig. 11).

Hog Ring

Fig. 11 Hog Ring

7. Apply anti-seize to the splines of the replacement CV

shaft prior to installation.

CV Joint Boot Replacement

Tool List Qty.

Needle Nose Pliers...................................................... 1

Wire Cutters ................................................................ 1

1. Remove the front axle assembly. See CV Shaft

Replacement on page 71.

2. Inspect the inner and outer CV joint boots (28) for

damage.

3. Cut the CV joint boot clamps (29) and (30) and

remove the CV joint boot (28).

4. Replace the new boot in reverse order of removal.

5. Install new boot clamps (Ref. Fig. 12).

CV Shaft

30

Fig. 12 CV Joint Boot

28

29

Front Strut Assembly Replacement

Tool List Qty.

Wheel Chocks..............................................................4

Floor Jack ....................................................................1

Jack Stands .................................................................4

Wrench, 18mm ............................................................1

Wrench, 19mm ............................................................1

Torque Wrench, ft. lbs..................................................1

Socket, 18mm..............................................................1

Socket, 19mm..............................................................1

Ratchet ........................................................................1

Inspect the strut cartridge for leaks at the seal. Replace if
leakage is found.

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Remove the front wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

4. Remove the nut (33) and bolt (45) that secure the top
of the strut assembly to the vehicle frame (Ref. Fig.

13).

B

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B

Spacer

33

Fig. 13 Upper Strut Bolt

5. Remove the nut (33), spacer (39) and bolt (46) that secure the bottom of the strut assembly to the lower control arm (See Fig. 1) (Ref. Fig. 14).

46

33

45

Fig. 15 Upper Control Arm Spacer

6. Remove the strut assembly from the vehicle.

7. The installation of the strut assembly is the reverse of disassembly.

8. Tighten the hardware to the torque values specified below:

Item Torque Specification

45, 33 70 - 77 ft. lbs. (95 - 105 Nm)

46, 33 70 - 77 ft. lbs. (95 - 105 Nm)

72

Fig. 14 Lower Strut Bolt

Lower Control Arm Assembly Replacement

Tool List Qty.

Wheel Chocks..............................................................4

Floor Jack ....................................................................1

Jack Stands .................................................................4

Plastic Faced Hammer.................................................1

Wrench, 15mm.............................................................1

Wrench, 17mm.............................................................1

Socket, 15mm..............................................................1

Socket, 17mm..............................................................1

Ratchet.........................................................................1

Torque Wrench, ft. lbs..................................................1

1. Lift and support vehicle. See LIFTING THE VEHI-
CLE on page 13.

2. Remove the front wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

Repair and Service Manual

668061

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

4. Remove the front spindle. See Front Spindle Removal on page 69.

5. Remove the nuts (28) and bolts (27) that secure each side of the lower control arm to the vehicle frame (Ref. Fig. 16).

28

27

Fig. 16 Lower Control Arm Removal

6. Remove the lower control arm from the vehicle.

7. Installation of lower control arm assembly is the reverse of removal.

NOTICE: Make sure bushings (21) and spacers (22)
are in place in the lower control arm before installa­tion (See Fig. 1).

1. Lift and support vehicle. See LIFTING THE VEHI­CLE on page 13.

2. Remove the front wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

4. Remove the front spindle. See Front Spindle Removal on page 69.

5. Remove front strut assembly. See Front Strut Assembly Replacement on page 71.

33

37

46

B

8. Tighten the hardware to the torque values specified below:

Item Torque Specification

27, 28 40 - 44 ft. lbs. (54 - 60 Nm)

Upper Control Arm Assembly Replacement

Tool List Qty.

Wheel Chocks ............................................................. 4

Floor Jack.................................................................... 1

Jack Stands................................................................. 4

Plastic Faced Hammer ................................................ 1

Wrench, 15mm ............................................................ 1

Wrench, 17mm ............................................................ 1

Wrench 18mm ...............................................................

Wrench 19mm ............................................................. 1

Socket, 15mm ............................................................. 1

Socket, 17mm ............................................................. 1

Socket,18mm .............................................................. 1

Socket, 19mm ............................................................. 1

Ratchet........................................................................ 1

Torque Wrench, ft. lbs. ................................................ 1

Fig. 17 Stabilizer Bar Linkage

6. Remove the nut (33), washers (37) and bolt (46) that
secure the stabilizer link to the upper control-arm
(Ref. Fig. 17). Check the rubber bushings for deterio­ration.

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

3. Remove the stabilizer bar.

4. Installation is the reverse of removal.

B

5. Tighten the hardware to the torque values specified below:

27

28

Fig. 18 Upper Control Arm Removal

7. Remove the nuts (28) and bolts (27) that secure each side of the upper control arm to the vehicle frame (Ref. Fig. 18).

8. Remove the upper control arm from the vehicle.

Installation of upper control arm assembly is the reverse
of removal.

NOTICE: Make sure bushings (21) and spacers (22)
are in place in the upper control arm before installa­tion (See Fig. 1).

Item Torque Specification

38, 33 70 - 77 ft. lbs. (95 - 105 Nm)

32, 28 30 - 33 ft. lbs. (40 - 45 Nm)

FRONT DIFFERENTIAL

Fill Plug

Drain Plug
(view of underside of
front differential)

9. Tighten the hardware to the torque values specified below:

Item Torque Specification

27, 28 70 - 77 ft. lbs. (95 - 105 Nm)

33, 46 40 - 44 ft. lbs. (54 - 60 Nm)

Stabilizer Bar Removal

Tool List Qty.

Ratchet ........................................................................ 1

Socket, 18mm.............................................................. 1

Socket, 17mm.............................................................. 1

Wrench, 18mm ............................................................ 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

1. Remove bolts (38), washers (37) and nuts (33) securing the stabilizer bar ends to the stabilizer bar linkages (Ref. Fig. 1).

2. Remove bolts (32) and nuts (28) that secure the sta­bilizer bar bracket to the vehicle frame.

Fig. 19 Fill and Drain Plugs

Check and replace the front differential oil at the intervals
indicated. See SCHEDULED MAINTENANCE CHART on
page 166.

Front Differential Oil Check

Tool List Qty.

Rag ...........................................................................AR

Drain Pan.....................................................................1

Ratchet.........................................................................1

Ratchet Extension........................................................1

Hex Bit, 8mm ...............................................................1

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Repair and Service Manual

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

NOTICE: Check the front differential oil at the Initial
Service and then at regular intervals indicated. See
SCHEDULED MAINTENANCE CHART on page 166.

Clean the areas around the fill and drain plugs with a
clean rag.

Remove the fill plug and inspect the oil for water or any
other contamination. If the oil is contaminated, it must be
replaced.

Front Differential Oil Replacement

Tool List Qty.

Rag........................................................................... AR

Drain Pan .................................................................... 1

Ratchet........................................................................ 1

Ratchet Extension ....................................................... 1

Hex Bit, 8mm............................................................... 1

1. Clean the areas around the fill and drain plugs with a clean rag.

2. Place a drain pan under the front differential.

3. Remove the drain plug from the bottom of the front differential and allow the oil to drain completely (Ref. Fig. 19).

4. Install the drain plug.

5. Remove the fill plug.

6. Add oil to full capacity. See RECOMMENDED LUBRICANTS AND FLUIDS on page 168.

7. Install the fill plug. Check for leaks.

Front Differential Replacement

Tool List Qty.

Wheel Chocks ............................................................. 4

Floor Jack.................................................................... 1

Jack Stands................................................................. 4

Ratchet........................................................................ 1

Socket, 13mm ............................................................. 1

Socket, 14mm ............................................................. 1

Wrench, 13mm ............................................................ 1

Wrench, 14mm ............................................................ 1

Pliers ........................................................................... 1

Screwdriver, Flat Tip, Large......................................... 1

Torque Wrench, ft. lbs. ................................................ 1

To prevent injury caused by inad­vertent movement of the differential,
a second person is required to sup-

port and assist in removing the differential.

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Remove the front wheel. See Wheel Removal on page 54.

3. Remove the CV shaft. Refer to CV Shaft Replace-
ment.

4. Remove the vent line (Ref. Fig. 20). Disconnect the differential power connection.

5. Remove the bolt (1) and nut (2) that secure the prop shaft to the differential.

6. Remove four bolts (3) that secure the front differen­tial to the frame. Carefully slide the differential off of
the prop-shaft splines and remove from the vehicle.

7. Installation of the differential (1) is in the reverse order of removal.

8. Tighten the hardware to the torque values specified below:

Item Torque Specification

1, 2 16 - 22 ft. lbs. (12 - 16 Nm)

3 27 - 31 ft. lbs. (37 - 42 Nm)

Vent Line

Differential
Power Connection

1

Prop
Shaft

2

CV Shaft

3

Fig. 20 Front Differential Replacement

Front of Vehicle

B

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

STEERING

B

30

17

Steering Column
Mount Weldment

16

26

16

23

22

26

23

24

27

14

20

27

5

6

19

Front of Vehicle

28

10

29

7

Part of Frame

3

8

2

15

Fig. 21 Steering Components (Non-EPAS)

2

3

9

15

76

Repair and Service Manual

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

5

6

B

Steering Column
Mount Weldment

16

26

17

30

10

7

17

16

23

23

22

26

24

19

27

14

Front of Vehicle

20

27

3

Brake Pedal

Mounting Bracket

9

668061

1

7

9

2

11

12

44

42

43

46

45

Fig. 22 Steering Component (EPAS)

Repair and Service Manual

77

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Steering Wheel Replacement

Tool List Qty.

Paint Marker ................................................................ 1

B

Socket, 24mm.............................................................. 1

Ratchet ........................................................................ 1

Hammer.......................................................................1

Ball Peen Hammer ......................................................1

Torque Wrench, ft. lbs..................................................1

Anti-Seize Compound............................................... AR

NOTICE: To maintain the correct orientation when
replacing the steering wheel, turn the wheels
straight ahead.

Mark the orientation of the steering wheel to the
steering shaft for proper alignment during assem­bly.

To prevent damage to the steering wheel cover, per­form the following removal procedure. Do not use a
screwdriver to pry the cover off.

1. Remove the steering wheel cover (5) by pulling it straight up (See Fig. 21) (See Fig. 22).

6

Fig. 23 Steering Wheel Nut Removal

2. Remove the lock nut (6) securing the steering wheel to the steering shaft (Ref. Fig. 23).

NOTICE: To prevent damage to the steering shaft,
do not use excessive force to strike the steering
shaft with the ball peen hammer.

3. With the aid of an assistant, place a ball peen ham­mer against the steering shaft end (24) and strike the
hammer with another hammer while applying upward
pressure to the steering wheel (Ref. Fig. 24) (See
Fig. 25).

4. Remove the steering wheel (Ref. Fig. 25).

Fig. 24 Steering Wheel Separation

24

Fig. 25 Steering Wheel Removal

5. Before installing the steering wheel, lightly coat the
splines of the steering shaft with (24) anti-seize com­pound (See Fig. 25).

6. With the wheels in the straight ahead position, align the steering wheel on the steering shaft (24) and slide the steering wheel onto the shaft.

7. Tighten the lock nut to the torque value specified below:

Item Torque Specification

6 20 - 22 ft. lbs. (27 - 30 Nm)

8. Install the steering wheel cover.

78

Repair and Service Manual

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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Steering Column Removal

Tool List Qty.

Paint Pen..................................................................... 1

Ratchet........................................................................ 1

Hex Bit Socket, 5/16”................................................... 1

Wrench, 10mm ............................................................ 1

Socket, 14mm ............................................................. 1

Socket, 17mm ............................................................. 1

Wrench, 14mm ............................................................ 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs. ................................................ 1

NOTICE: Mark the orientation of the steering com­ponents for proper alignment during assembly.

Remove the steering wheel.

Remove the bolt (17) and washer (30) that secure the
steering shaft (10) to the steering wheel shaft (24) (Ref.
Fig. 21)(Ref. Fig. 26).

The steering wheel shaft (24), and bushings may be
removed for inspection or replacement at this point.

9. Installation is the reverse order of removal.

10. Tighten the hardware to the torque values specified

Fig. 27 Steering Column Assembly

below:

B

Fig. 26 Steering Column

Remove the bolts (26) and nuts (27) that secure the tilt
adjuster (20) to the vehicle. Remove the tilt adjuster.

Remove the bolts (16) and nuts (14) that secure the
steering column assembly to the vehicle. Remove steer­ing column (Ref. Fig. 27).

Item Torque Specification

17 22 - 26 ft. lbs. (30 - 35 Nm)

26, 27 4 - 5 ft. lbs. (5 - 7 Nm)

16, 14 18 - 22 ft. lbs. (25 - 30 Nm)

Steering Shaft Replacement (Non-EPAS)

Tool List Qty.

Paint Pen .....................................................................1

Socket, 14mm..............................................................1

Socket, 17mm..............................................................1

Ratchet ........................................................................1

Wrench, 14mm ............................................................1

Wrench, 17mm ............................................................1

Torque Wrench, ft. lbs..................................................1

NOTICE: Mark the orientation of the steering com­ponents for proper alignment during assembly.

1. Remove the steering wheel. See Steering Wheel Replacement on page 78.

2. Remove the bolt (17) and washer (30) from the top of the steering shaft (10) (Ref. Fig. 21)(Ref. Fig. 28).

3. Remove bolt (29) and nut (28) from the bottom of the steering shaft (10).

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B

Fig. 28 Steering Shaft

4. Replace the steering shaft (10) in the reverse order of removal.

5. Tighten the hardware to the torque values specified below:

Item Torque Specification

17 22 - 26 ft. lbs. (30 - 35 Nm)

29, 28 44 - 48 ft. lbs. (60 - 65 Nm)

1. Disconnect the two wire harness connections on the EPAS unit (Ref. Fig. 29).

Disconnect

Fig. 29 EPAS Harness Connectors

2. Remove the bolt (17) and nut (7) that secure the upper steering shaft (10) to the EPAS unit (1) (Ref. Fig. 30) (Ref. Fig. 22).

3. Remove the bolt (43) and nut (44) that secure the lower steering shaft (42) to the EPAS unit (1) (Ref. Fig. 31).

4. Remove the bolts (9) and nuts (7) that secure the EPAS unit and mounting plate (2) to the vehicle frame (Ref. Fig. 22).

5. Remove the EPAS unit from the vehicle.

Electric Power Assist System (EPAS) (If Equipped)

Tool List Qty.

Paint Pen ..................................................................... 1

Socket, 13mm.............................................................. 1

Socket, 17mm.............................................................. 1

Ratchet ........................................................................ 1

Ratchet Extension .......................................................1

Wrench, 13mm ............................................................ 1

Wrench, 17mm ............................................................ 1

Torque Wrench, ft. lbs..................................................1

NOTICE: Mark the orientation of the steering compo­nents for proper alignment during assembly.

Fig. 30 EPAS Steering Shaft

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Repair and Service Manual

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2. Remove the nut (28) and bolt (29) securing the
steering shaft yoke to the steering rack (Ref. Fig.

32).

B

Fig. 31 Lower Steering Shaft

6. Installation of the EPAS unit is the reverse order of removal.

7. Tighten the hardware to the torque values specified below:

Item Torque Specification

17, 7 22 - 26 ft. lbs. (30 - 35 Nm)

46, 45 22 - 26 ft. lbs. (30 - 35 Nm)

9, 7 22 - 26 ft. lbs. (30 - 35 Nm)

Steering Rack Replacement

Tool List Qty.

Paint Pen..................................................................... 1

Allen Wrench, 6mm ..................................................... 1

Wrench, 13mm ............................................................ 1

Straight Blade Screwdriver.......................................... 1

Socket, 13mm ............................................................. 1

Ratchet........................................................................ 1

Torque Wrench, ft. lbs. ................................................ 1

NOTICE: Mark the orientation of the steering compo­nents for proper alignment during assembly.

1. Remove the hardware securing the steering rack ball joints (3) to the spindles. Refer to Front Spindle Removal.

7

28

Part of
Frame

4

3

8

2

Front of Vehicle

Fig. 32 Steering Rack

3. Remove the three socket head bolts (8) and two hex
bolts and nuts (7) attaching the steering rack assem­bly to the frame.

4. Steering rack replacement is the reverse order of removal.

5. Tighten nuts to the torque values specified below:

Item Torque Specification

8, 7 17 - 20 ft. lbs. (23 - 27 Nm)

9, 7 17 - 20 ft. lbs. (23 - 27 Nm)

Steering
Shaft

29

9

Rack Ball Joint Replacement

Tool List Qty.

Wrench, 17mm ............................................................2

1. Remove the nut (2) that secures the rack ball joint (3) to the spindle. See Spindle Removal.

2. Remove the rack end ball joint (3) from the steering rack by loosening the jam nut (4) and un-threading the ball joint off the rack (Ref. Fig. 32).

3. Installation is the reverse order of removal.

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NOTICE: Wheel alignment is required after installa­tion. See Wheel Alignment.

4. Tighten the hardware to the torque values specified

B

below:

Item Torque Specification

2 17 - 20 ft. lbs. (23 - 27 Nm)

MAINTENANCE

Consistent routine maintenance of the front suspension
and steering consists of routine lubrication. See SCHED-
ULED MAINTENANCE CHART on page 166. Use only
recommended lubricants.

Examination of the tires will provide indications that an
alignment is required.

NOTICE: Some maintenance items must be serviced
more frequently on vehicles used under severe driv­ing conditions.

Wheel Alignment

Tool List Qty.

Floor Jack .................................................................... 1

Jack Stands ................................................................. 2

Wheel Chocks .............................................................4

Measuring Tape........................................................... 1

Wrench, 17mm ............................................................ 2

1. To center the steering unit in the middle of its travel, turn the steering wheel to the left until the it contacts the steering stop.

2. Rotate the wheel to the right while counting the num­ber of turns required to contact the right steering
stop. Divide the number of turns by two. This indi­cates the number of steering wheel turns required to
achieve center.

Roll the vehicle forward 10 feet (3 meters). Measure the
center tread distance at the front of the tires (Ref. Fig.

33). Measure as close to parallel with the front lower

frame of the vehicle as possible.

Fig. 33 Wheel Alignment Front of Front Tires

3. Similarly, measure the center tread distance on the rear of the front tires. The correct measurement is 0 to 1/8 inch (0 - 3.2mm) toe in.

NOTICE: Counting threads or measuring thread dis­tance are both acceptable methods to equalize tie
rod length.

4. To adjust the wheel alignment, loosen the tie rod jam nut (42), holding the hex form on the tie rod (44) (Ref. Fig. 34).

82

5. If the tie rods or ends have been replaced, adjust both rods the same distance prior to reinstalling them on the vehicle. After adjustment, tighten the jam nut (42) to the torque value specified below:

Repair and Service Manual

Fig. 34 Wheel Alignment

Item Torque Specification

42 20 - 25 ft. lbs. (27 - 34 Nm)

668061

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

6. Test drive the vehicle and confirm that the steering
wheel is correctly centered. If not, remove the steer­ing wheel and rotate it to the correct position.

STEERING WHEEL

~1 inch
(25 mm)

Fig. 35 Steering Wheel Play

Perform scheduled maintenance on the steering system.
See SCHEDULED MAINTENANCE CHART on
page 166.

Inspect the steering operation before each use using the
following procedure:

1. Park the vehicle on a level surface.

2. Lightly turn the steering wheel to the left and then to the right.

3. There should be ~1 inch (25 mm) of free play (Ref. Fig. 35).

4. If there is excessive play, unusual noises, or the steering feels rough, have the steering system inspected by your TEXTRON OFF ROAD dealer.

preference. A shock adjustment tool is recommended.

To adjust, rotate the adjustment cam (Ref. Fig. 36):

• to the right to increase spring pre-load (ride height)

• to the left to decrease spring pre-load (ride height)

B

RIDE HEIGHT ADJUSTMENT

Fig. 36 Ride Height Adjustment

The spring pre-load adjuster can be adjusted on the front
and rear shock absorber springs to suit your needs and

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Repair and Service Manual

83

FRONT CV SHAFT, SUSPENSION AND STEERING

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

84

Repair and Service Manual

668061

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR AXLE AND SUSPENSION

Front of Vehicle

12

14

27

6

7

20

27

24

28

28

19

15

16

18

31

21

30

22

30

8

7

12

8

12

15

4

5

17

15

20

12

14

1

21

25

20

2

20

Fig. 1 Rear Suspension Components

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Repair and Service Manual

85

REAR AXLE AND SUSPENSION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR SUSPENSION

NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise

B

specified. If torque values are not specified. See
TORQUE SPECIFICATIONS on page ix.

Maintenance

See SCHEDULED MAINTENANCE CHART on
page 166. Use only the recommended lubricants. See
RECOMMENDED LUBRICANTS AND FLUIDS on
page 168.

Routine examination of the tires will indicate if an align­ment is required.

Lubrication points are located on the upper and lower
control arms and the spindle. Use a maximum of three
pumps of grease per fitting.

Wheel Bearing Test

To check for worn wheel bearings, perform the following
procedure:

NOTICE: The axle nut must be installed at the
proper torque for the wheel bearing test to be accu­rate.

4. At the center of the hub, remove the cotter pin (5),
axle nut (4) and washer (17) from the axle. (Ref. Fig.

2)(Ref. Fig. 3)

5

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Grasp the wheel at the top and bottom of the tire.

3. Apply firm back and forth pressure on the wheel. If any movement is noted, the wheel bearing must be pressed out of the spindle and replaced.

To reduce the possibility of per­sonal injury, follow the lifting proce­dure in SAFETY section of this

manual.

Hub Removal

Tool List Qty.

Wheel Chocks .............................................................4

Floor Jack .................................................................... 1

Jack Stands ................................................................. 4

Hammer, Plastic .......................................................... 1

Needle Nose Pliers......................................................1

Impact Wrench ............................................................1

Impact Socket, 27mm..................................................1

Torque Wrench, ft. lbs..................................................1

Anti-seize Compound ............................................... AR

1. Lift and support the vehicle. See LIFTING THE VEHICLE on page 13.

2. Remove the rear wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

Fig. 2 Cotter Pin

24

23

Fig. 3 Axle Nut and Washer

86

Repair and Service Manual

668061

REAR AXLE AND SUSPENSION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

5. Tap the hub with a plastic hammer while applying outward pressure until the hub slides off the splines of the axle (Ref. Fig. 4).

Fig. 4 Remove Hub

6. Clean the splines of the hub and axle and apply anti­seize compound before installation.

7. The installation of the hub is the reverse of disas­sembly.

8. Tighten the hardware to the torque values specified below:

Item Torque Specification

4 180 - 199 ft. lbs. (245 - 270 Nm)

9. Install a new cotter pin through the axle nut and axle. Bend the cotter pin (5) around the axle to secure (See Fig. 2).

1. Lift and support vehicle. See LIFTING THE VEHI-
CLE on page 13.

2. Remove the rear wheel. See Wheel Removal on page 54.

3. Remove the brake caliper from the rotor. See Brake Pad Replacement on page 60.

4. Remove the hub. See Hub Removal on page 86.

40

20

8

Fig. 5 Spindle

5. Remove the bolt (8) and nut (20) that secure the
spindle (40) to the upper control arm (1) (Ref. Fig.

1)(Ref. Fig. 5).

6. Remove the bolt (8) and nut (20) that secure the spindle (40) to the lower control arm (2) (See Fig. 1) (Ref. Fig. 6). Slide the spindle assembly off the CV axle splines.

B

Rear Spindle Removal

Tool List Qty.

Wheel Chocks ............................................................. 4

Floor Jack.................................................................... 1

Jack Stands................................................................. 4

Hammer....................................................................... 1

Needle Nose Pliers...................................................... 1

Ratchet........................................................................ 1

Socket,17mm .............................................................. 1

Socket, 19mm ............................................................. 1

Wrench, 17mm ............................................................ 1

Wrench, 19mm ............................................................ 1

Torque Wrench, ft. lbs. ................................................ 1

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Repair and Service Manual

87

REAR AXLE AND SUSPENSION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

6. Remove the CV shaft from the differential using a pry bar. Make sure that the hog ring is in place on the CV shaft splines (Ref. Fig. 7).

B

Hog Ring

Fig. 7 Hog Ring

7. Apply anti-seize compound to the splines of the replacement CV shaft prior to installation.

CV Joint Boot Replacement

Tool List Qty.

Fig. 6 Remove Spindle

7. Remove the spindle assembly from the vehicle.

8. The installation of the spindle assembly is the reverse of disassembly.

9. Tighten the hardware to the torque values specified below:

Item Torque Specification

8, 20 40 - 44 ft. lbs. (54 - 60 Nm)

Needle Nose Pliers ......................................................1

Wire Cutters.................................................................1

1. Remove the rear axle assembly. See CV Shaft Replacement on page 88.

2. Inspect the inner and outer CV joint boots (28) for damage.

3. Cut the CV joint boot clamps (29) and (30).

4. Remove the CV joint boot (28).

5. Replace the new boot and clamps in the reverse order of removal (Ref. Fig. 8).

CV Shaft Replacement

Tool List Qty.

Pry Bar......................................................................... 1

Drain Pan..................................................................... 1

Anti-seize Compound ............................................... AR

NOTICE: Inspect the axle (shaft) for contamination,
especially if the CV boots are torn. Replace the rear
axle if any contamination is found.

1. Lift and support vehicle. See LIFTING THE VEHI­CLE on page 13.

2. Remove the rear wheel. See Wheel Removal on page 54.

3. Remove the brake calipers from the rotor. See Brake Pad Replacement on page 60.

4. Remove the hub. See Hub Removal on page 86.

5. Remove the spindle assembly. See Rear Spindle Removal on page 87.

88

Repair and Service Manual

CV Shaft

30

Fig. 8 CV Boot Replacement

28

29

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