Cargo Bed; Cargo Bed Removal; Cargo Bed Installation - Pioneer 1200 Maintenance Service Manual

BODY AND TRIM

CARGO BED

See General Warning, Section 1, Page 1-1.

CARGO BED REMOVAL

NOTE: The following procedures will be easier with the help of an additional person.
1. Pioneer 1200:
Prop rods (1) (CCI P/N 1015348) and (25) (CCI P/N 102301401) are not interchangeable
(Figure 4-5, Page 4-10).
1.1. Raise bed and ensure that the prop rod (1) or (25) is secured in the prop rod track (2). Hold bed
securely in an upright position. Remove cotter pin (3) and flat washer (4) from top end of prop rod
where prop rod attaches to bed. Remove prop rod (1) or (25) from bed and place prop rod between
prop rod track (2) and rear body panel. Lower bed onto vehicle frame (Figure 4-5, Page 4-10).
1.2. Remove two 3/8-16 nylon lock nuts (8) from left and right cargo bed hinge/bolt assemblies.
1.3. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges, and
remove the 3/8 x 3-3/8-inch hinge bolts (9) from the hinge assemblies.
1.4. Raise rear edge of bed approximately 6 inches (15.2 cm) and pull bed assembly toward rear of vehi-
cle (approximately 3 inches (7.6 cm)) to release bed latch assembly (10) from latch plate (11) and
lift bed from vehicle.
2. Pioneer 1200SE:
2.1. Remove two 3/8-16 nylon lock nuts (2) from left and right cargo bed hinge/bolt assemblies
(Figure 4-6, Page 4-11).
2.2. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges, and
remove the 3/8 x 3-3/8-inch hinge bolts (1) from the hinge assemblies.
2.3. Raise rear edge of bed approximately 6 inches (15.2 cm) and pull bed assembly toward rear of vehi-
cle (approximately 3 inches (7.6 cm)) to release bed latch assembly (6) from latch plate (11) and
lift bed from vehicle.

CARGO BED INSTALLATION

NOTE: The following procedure will be easier with the help of an additional person.
1. Pioneer 1200:
1.1. Hold front of bed lower than rear of bed and place front edge of bed onto vehicle frame and align
latches (10) with latch plates (11) (Figure 4-5, Page 4-10).
1.2. Lower rear edge of bed onto vehicle and align frame hinge brackets (14) with bed hinge brackets
(15).
1.3. Start the bolts (9) into left and right hinge assemblies. Use an alignment tool if necessary.
1.4. Use a small hammer to lightly tap bolts through hinge assembly.
1.5. Install nylon lock nut (8) on each bolt (9) and tighten to 15 ft-lb (21 N·m).
1.6. Lift bed from bed latch and with prop rod in a slot notch, place prop rod (1) or (25) in bed mounting
hole and install flat washer (4) and a new cotter pin (3) onto prop rod.
1.7. Proceed to Bed Stop Bumper Adjustment on page 4-11.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
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Cargo Bed
Page 4-9