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.
Page 3
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: 1-800-774-3946 FAX: 1-800-448-8124
Service Parts PHONE: 1-888-438-3946
International:
PHONE: 001-706-798-4311 FAX: 001-706-771-4609
668061
Repair and Service Manual
i
Page 4
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.
ii
Repair and Service Manual
668061
Page 5
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.
668061
Repair and Service Manual
iii
Page 6
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.
iv
Repair and Service Manual
668061
Page 7
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.
668061
Repair and Service Manual
v
Page 8
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.
ITEMSERVICE OPERATION
BatteryCharge battery.
SeatsRemove protective plastic covering.
Brakes
Tires
Fuel
EngineCheck 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
vi
Repair and Service Manual
668061
Page 9
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.
668061
Repair and Service Manual
vii
Page 10
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
viii
Repair and Service Manual
668061
Page 11
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)
M4M5M6M8M10M12M14
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
668061
Repair and Service Manual
ix
Page 12
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:
x
Repair and Service Manual
668061
Page 13
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
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
8
Repair and Service Manual
668061
Page 21
Notes:
TABLE OF CONTENTS
668061
Repair and Service Manual
9
Page 22
TABLE OF CONTENTS
Notes:
10
Repair and Service Manual
668061
Page 23
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
Page 24
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
668061
Page 25
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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
Page 26
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
Page 27
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.
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.
668061
Repair and Service Manual
15
Page 28
BODY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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
Page 33
BODY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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
Page 36
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
Page 37
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.
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.
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
Page 48
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
Page 49
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
Page 50
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.
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 NOTORQUE 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).
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).
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).
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 NOTORQUE 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
Page 52
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.
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.
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 NOTORQUE SPECIFICATION
40
8
Repair and Service Manual
37 - 41 ft.lbs. (50 - 55 Nm)
668061
Page 53
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).
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 NOTORQUE SPECIFICATION
16
Seatbelt
Retractor
18
Mounting
Bracket
15
2
Fig. 8 Seat Belt
2
19
Front of Vehicle
18, 1948 - 52 ft.lbs. (65 - 71 Nm)
15, 1648 - 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
Page 54
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
Page 55
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
Page 56
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
Page 57
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
Page 58
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 ListQuantity
B
Back Brace .................................................................. 2
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
Page 60
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
Page 61
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 ListQty.
Deep Well Socket, 15 mm ...........................................1
Wrench, 15 mm ...........................................................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.
668061
Repair and Service Manual
49
Page 62
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
Page 63
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
668061
Repair and Service Manual
51
Page 64
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
Page 65
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
Page 66
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.
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.
ITEMTORQUE SPECIFICATION
Lug Nut85 - 100 ft. lbs. (115 - 135 Nm)
54
Repair and Service Manual
668061
Page 67
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
Page 68
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
Page 69
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
Page 70
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
Page 71
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.
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
Page 72
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:
ItemTorque 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.
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
60
Repair and Service Manual
668061
Page 73
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.
ItemTorque Specification
B
23
22
15
19
30
9.Replace the wheel. See Wheel Installation on
page 54.
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
Page 74
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:
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.
62
Repair and Service Manual
668061
Page 75
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.
.
ItemTorque Specification
BRAKE AND ACCELERATOR PEDALS
Brake Pedal Removal And Installation
Tool ListQty.
Needle Nose Pliers ......................................................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 Valve38 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.
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
Page 81
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:
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
Page 82
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
ItemTorque Specification
217 - 20 ft. lbs. (23 - 27 Nm)
3018 - 22 ft. lbs. (24 - 30 Nm)
668061
Page 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.
FRONT AXLE
CV Shaft Replacement
Tool ListQty.
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 ListQty.
Needle Nose Pliers...................................................... 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.
668061
Repair and Service Manual
73
Page 86
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.
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).
ItemTorque Specification
38, 3370 - 77 ft. lbs. (95 - 105 Nm)
32, 2830 - 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:
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:
ItemTorque Specification
1, 216 - 22 ft. lbs. (12 - 16 Nm)
327 - 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
668061
Repair and Service Manual
75
Page 88
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
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
668061
Page 89
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.
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
Page 90
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.
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:
ItemTorque Specification
620 - 22 ft. lbs. (27 - 30 Nm)
8.Install the steering wheel cover.
78
Repair and Service Manual
668061
Page 91
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.
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.
668061
Repair and Service Manual
81
Page 94
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.
NOTICE: Wheel alignment is required after installation. See Wheel Alignment.
4.Tighten the hardware to the torque values specified
B
below:
ItemTorque Specification
217 - 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 ListQty.
Floor Jack .................................................................... 1
Jack Stands ................................................................. 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
ItemTorque Specification
4220 - 25 ft. lbs. (27 - 34 Nm)
668061
Page 95
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
668061
Repair and Service Manual
83
Page 96
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
Page 97
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
668061
Repair and Service Manual
85
Page 98
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
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
Page 99
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:
ItemTorque Specification
4180 - 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.