1 OF 17 A 1. PURPOSE: Instructions for in field replacement of 9004 mechanical suspension top pan 2. SCOPE: 9004 mechanical suspension with legacy two point LX back frame and current LX back frame 3. PROCEDURE: 3.1. Materials Required: 3.1.1. (QTY-1) P/N 1100-621311-000 KIT/TOP PAN ASSY/ MOUNT ON 9004 SEAT 3.1.2. Permanent thread locker such as red Loctite 271 or equivalent 3.1.3. Permanent thread locker such as blue Loctite 242 or equivalent 3.1.4. Super bond adhesive such as Loctite -495 or equivalent. 3.1.5. Brake or parts cleaner (S00705 or equivalent) 6 1 9901-612922-003 TOP PAN/STATIC/ASSEMBLY 5 2 9906-000018-000 WASHER FLAT\PLATED\7/16\GR8 4 2 9904-000003-000 SCREW HEX HD/7/16-20X1.5" 3 15 9901-500214-000 BELLOW RIVET 2 2 40664 SPACER/BACK TO SUSPENSION 1 2 9902-500396-000 BOLT REAR BEARNG/NO PROFILE ITEM QTY PART NUMBER DESCRIPTION P/N 1100-621311-000 KIT/TOP PAN ASSY/ MOUNT ON 9004 SEAT 3.2. Tools Required: 3.2.1. Philip Head screw driver 3.2.2. Rubber Hammer 3.2.3. Rivet Puller 3.2.4. Knob Wrench 3.2.5. 17mm Wrench 3.2.6. Torque Wrench 3.2.7. Ratchet Wrench 3.2.8. 13mm socket 3.2.9. 15mm socket 3.2.10. 5/8 socket 3.2.11. Flat Jaw Channel Pliers 3.2.12. Flat Head screw driver 3.2.13. 8 mm Hex Key or Hex Driver 3.2.14. T-45 Torx-bit socket
2 OF 17 A 3.2.15. 5/16 Hex-bit key (Allen Key) 3.2.16. Adjustable Wrench 3.2.17. 29/64 Drill Bit 3.2.18. Drill 3.2.19. Iron wire brush 3.2.20. Black Spray Paint 3.2.21. Torque wrench 0 to 100 ft-lbs 3.2.22. Protractor 3.2.23. Dynafile sander 3.3. Process: 3.3.1. Remove seat cushion to expose top pan : 3.3.1.1. Removed the four gear knobs from the right and left side of the top pan with a 17mm Wrench (see picture 1). Picture 1 3.3.1.2. Remove the plastic rivets with a rivet puller or flat head screwdriver to release bellow from suspension top pan. Then, remove the rivets from seat cover flap and the bellow in the rear of the suspension. Next, use a flat head screwdriver to help peel bellow off the back frame feet and along the top pan. (see pictures 2, 3, 4 and 5).
3 OF 17 A Picture 2 Picture 3 Picture 4 Picture 5 3.3.1.3. Remove seat cushion by pushing on the seat cover down to on both sides and front to release the j-hook from the metal runner on the top pan. A flat head screw driver may be needed to release the j-hook. Then, remove the cushion and cover out from the Mechanical suspension (see pictures 6 and 7). Picture 6 Picture 7 3.3.2. Remove the Legacy two point LX back frame : 3.3.3. Remove the front M8 mounting bolts with a 13mm socket and ratchet wrench from back frame (see picture 7). Then remove the rear 7/16-20 hex screws use a
4 OF 17 A 5/8 socket and ratchet wrench (see picture 8). Next, remove the back from the Mechanical suspension. Note: If a lap belt retractor and a lap belt receptor are used then remove the original belt retractor using a 5/8 socket ratchet wrench and retain the original 7/16 hardware, belt spacers and belt. Picture 8 Picture 9 3.3.3.1. Use a 8 mm Hex Driver or a T-45 Torx-bit socket to remove the M10 shoulder bolt from the top pan slewing bracket (see picture 10) and remove the rear M10 no profile scissor screw (see picture 11). Next, remove the Mechanical top pan from the suspension. Picture 10 Picture 11 3.3.4. Remove the current LX back frame : 3.3.4.1. Remove the front 7/16-20 hex screws use a 5/8 socket ratchet wrench (see pictures 12 & 13). Next, remove the 7/16-20 hex screws from the belt retractor and from the lap receptor using a 5/8 socket ratchet wrench. Then, remove rear M10 flange bolts from back frame using a 15mm socket ratchet wrench (see pictures 12 & 13).
5 OF 17 A Picture 12 Picture 13 3.3.4.2. Next, remove the 7/16-20 hex screws from shoulder belt retractor at the rear top pan mounting bracket (see picture 14). Picture 14 3.3.4.3. Now, use a 8mm Hex Driver or a T-45 Torx-bit socket to remove the M10 shoulder bolt from the top pan slewing bracket (see picture 10). Next, remove the Mechanical top pan from the suspension. 3.3.5. Suspension lock post modification and top pan height adjusting position along the lock post cut groove: 3.3.5.1. Measure from the top of the lock post down 1-1/8 inch, mark and a use wheel saw to remove this section of material (see pictures 15, 16, 17 & 18).
6 OF 17 A Picture 15 Picture 16 Picture 17 Picture 18 3.3.5.2. Use a Dynafile sander along the top of the lock post and spray paint the lock post black (see pictures 19 & 20). Picture 19 Picture 20
7 OF 17 A 3.3.5.3. The top pan static height adjusting must interface with the lock post cut groove (see pictures 21, 22, 23 & 24). Height adjusting Lock post cut groove Picture 21 Picture 22 Left side height adjusting interface with the lock post cut groove. Picture 23 Picture 24 3.3.6. Install the Legacy two point LX back frame : Right side height adjusting interface with the lock post cut groove. 3.3.6.1. Modify the back frame foot: With the back frame secured, drill out the front 8mm mounting thru hole on the back frame foot with a 29/64 drill bit and drill (see picture 25). Repeat this step for the opposite side back frame foot.
8 OF 17 A Drill front mounting hole with 29/64 drill Picture 25 3.3.6.2. Use the parts cleaner and an iron wire brush to clean every bolt. Also, use the parts cleaner and an iron wire brush to clean out the threaded suspension scissor holes. 3.3.6.3. Apply permanent thread locker such as red Loctite 271 or equivalent on both M10 shoulder bolts. Use a 8mm Hex Driver or T-45 Torx-bit socket to install the M10 shoulder bolt through the top pan upper slewing bracket and the threaded suspension scissor hole (see pictures 26 & 27). Use a torque wrench and torque both M10 shoulder bolts to 42 N-M (31 LB-FT). Picture 26 Picture 27 3.3.6.4. Use channel pliers to remove the steel bushings from the top pan rear (see picture 28).
9 OF 17 A 3.3.6.5. Apply permanent thread locker such as blue Loctite 242 or equivalent on both M10 no profile scissor screws. Use a T-45 Torx-bit socket to install the rear M10 no profile scissor screw through the top pan rear thru hole and the threaded suspension scissor hole (see picture 29). Use a torque wrench and torque both M10 no profile scissor screws to 42 N-M (31 LB-FT). Picture 28 Picture 29 3.3.6.6. Apply permanent thread locker such as red Loctite 271 or equivalent on the 7/16-20 screws. 3.3.6.7. Place the legacy two point LX back frame onto the top pan rear. Then, insert the 7/16-20 screw with the 7/16 flat through the rear back frame foot hole. Next, insert the second 7/16-20 screw with the 7/16 flat through the opposite side rear back frame foot hole. 3.3.6.8. Next, insert the 7/16-20 screw with the 7/16 flat through the front back frame foot hole. Then, insert the second 7/16-20 screw with the 7/16 flat through the opposite side front back frame foot hole. 3.3.6.9. Use a 5/8 socket ratchet wrench to secure all four 7/16-20 screws and use a torque wrench to torque the 7/16-20 screws 80 N-M (60 LB-FT) (see picture 30).
10 OF 17 A Picture 30 3.3.6.10. Note: If a lap belt retractor and a lap belt receptor are used then apply permanent thread locker such as red Loctite 271 or equivalent on both 7/16-20 screw from the belt (see drawing 1). 3.3.6.11. Insert the 7/16 flat washer with the new 7/16-20 screw through and to the front back frame foot hole. Then, insert the second new 7/16-20 screw with the 7/16 flat washer through the opposite side front back frame foot hole (see drawing 1). 3.3.6.12. Next, insert the 7/16 flat washer with the 7/16-20 screw through the belt retractor, through the belt spacer and through the left side rear back frame foot hole and (see drawing 1). 3.3.6.13. Then, insert the 7/16 flat washer with the 7/16-20 screw through the belt receptor, through the belt spacer and through the right side rear back frame foot hole and (see drawing 1). 3.3.6.14. Use a 5/8 socket ratchet wrench to secure belt receptor and the belt retractor. Note: The belt receptor and the belt retractor must make an angle of 60 degrees with horizontal. Use a protractor to verify that the 60 degrees receptor matches the 60 degrees belt retractor angle. 3.3.6.15. Now use a 5/8 socket ratchet wrench to torque the four 7/16-20 back frame feet screws to 80 N-M (60 LB-FT) (see drawing 1).
11 OF 17 A Drawing 1 3.3.7. Install the current LX back frame : 3.3.7.1. Use the parts cleaner and an iron wire brush to clean every bolt. Also, use the parts cleaner and an iron wire brush to clean out the threaded suspension scissor holes. 3.3.7.2. Apply permanent thread locker such as red Loctite 271 or equivalent on both M10 shoulder bolts. Use a 8mm Hex Driver or T-45 Torx-bit socket to install the M10 shoulder bolt through the top pan upper slewing bracket and the threaded suspension scissor hole (see pictures 26 & 27). Use a torque wrench and torque both M10 shoulder bolts to 42 N-M (31 LB-FT). 3.3.7.3. Place the one new back to suspension spacer over the rear top pan steel bushing and repeat this step for the opposite side (see picture 31). Then, place the current LX back frame onto the top pan rear by inserting
12 OF 17 A the rear back frame foot hole through the steel bushing and repeat this step for the opposite side (see picture 31). 3.3.7.4. Next, apply permanent thread locker such as blue Loctite 242 or equivalent on both M10 flange bolts. Then, insert the M10 flange bolt through the rear back frame rear foot hole and through the threaded suspension scissor hole (see pictures 31, 32 & 33). Repeat this step for the opposite side back frame foot (see picture 33). Picture 31 Picture 32 Picture 33 Picture 34 3.3.7.5. Insert the 7/16 flat washer with the new 7/16-20 screw through and to the front back frame foot hole. Then, insert the second new 7/16-20 screw with the 7/16 flat washer through the opposite side front back frame foot hole (see pictures 35, 36, 37 & 38 and drawing 2).
13 OF 17 A 3.3.7.6. Next, insert the 7/16 flat washer with the 7/16-20 screw through the belt retractor, through the belt spacer and through the left side rear back frame foot hole and (see pictures 35, 36, 37 & 38 and drawing 2). 3.3.7.7. Then, insert the 7/16 flat washer with the 7/16-20 screw through the belt receptor, through the belt spacer and through the right side rear back frame foot hole and (see pictures 35, 36, 37 & 38 and drawing 2). 3.3.7.8. Use a 5/8 socket ratchet wrench to secure belt receptor and the belt retractor. Note: The belt receptor and the belt retractor must make an angle of 60 degrees with horizontal. Use a protractor to verify that the 60 degrees receptor matches the 60 degrees belt retractor angle. 3.3.7.9. Now use a 15mm socket ratchet wrench to torque the two M10 flange bolts to 42 N-M (31 LB-FT) (see pictures 35, 36, 37 & 38 and drawing 2). 3.3.7.10. Now use a 5/8 socket ratchet wrench to torque the four 7/16-20 back frame feet screws to 80 N-M (60 LB-FT) (see pictures 35, 36, 37 & 38 and drawing 2). Picture 35 Picture 36
14 OF 17 A Picture 37 Picture 38 3.3.7.11. Next, insert the 7/16 flat washer with the 7/16-20 screw through the rear shoulder belt retractor. 3.3.7.12. Now verify the location pin on the belt retractor mates with the 90 degree alignment slot on the left rear top pan mounting. 3.3.7.13. Use a 5/8 socket ratchet wrench to secure the 7/16 flat washer with the 7/16-20 screw through the shoulder belt retractor and to the alignment slot on the left rear top pan mounting bracket (see picture 14 and drawing 2). 3.3.7.14. Use a torque wrench and torque the 7/16-20 screw to 80 N-M (60 LB-FT).
15 OF 17 A Drawing 2 3.3.8. Install the seat cushion onto the top pan : 3.3.8.1. Place the seat cushion back into its original position on the top pan. 3.3.8.2. Fold the j-hooks under, push down on seat cushion cover, and reinsert j- hooks into metal runners. Use a rubber hammer to bend the metal runners inward to secure the cover (see pictures 41, 42 & 43).
16 OF 17 A Picture 41 Picture 42 Picture 43 3.3.8.3. Reattach the rear seat cushion cover flap with new rivets. 3.3.8.4. Position the bellow along the suspension top pan to its original position and back frame feet. Reattach the bellow with new rivets; then insert the rivets through the bellow and into the top pan, if necessary apply super bond 495 to the bellow to secure loose edge to the suspension top pan and the bellow to the back frame foot (see picture 44). 4. INSPECTION: Picture 44 3.3.8.5. Finally, install the on knobs back on the suspension top pan. Place a lock washer and thread the knob onto the suspension top pan height adjustment rod; then hold the knob and use a 17mm wrench to tighten the M10 jam nut knob. Repeat this step for the opposite side knob. Then, repeat this step for the suspension top pan height tilt adjustment rod. 4.1. Check that all screws and nuts are fastened securely. 4.2. Check the top pan static height adjusting is interfaced with the lock post cut groove (see pictures 23 & 24). 4.3. Ensure bellow is secure. 4.4. Ensure seat travels up and down smoothly. 4.5. Ensure that the belt travels in and out without rubbing against the retractor.
17 OF 17 A 4.6. Verify that the receptor matches the lap belt retractor angle of 60 degrees. 4.7. Ensure that the location pin on the shoulder belt retractor mates with the alignment slot on the top pan mounting bracket. 4.8. Verify that the shoulder belt retractor forms an angle of 90 degrees with the floor. 4.9. Check that all screws and nuts are fastened securely.