USE OF HEAT DURING REPAIR
| WARNING | Chrysler Group LLC engineering's position on the use of heat during collision repair is as follows: Any body panel or frame component damaged which is to be repaired and reused, must be repaired using the "cold straightening" method. No heat may be used during the straightening process. During rough straightening prior to panel replacement, damaged panels or frame components may be heated to assist in body/frame realignment. The application of heat must be constrained to the parts which will be replaced and not allowed to affect any other components. This "no heat" recommendation is due to the extensive use of high strength and advanced high strength steels in Chrysler Group LLC products. High-strength materials can be substantially and negatively affected from heat input which will not be obviously known to the repairer or consumer. Ignoring these recommendations may lead to serious compromises in the ability to protect occupants in a future collision event, reduce the engineered qualities and attributes, or decrease the durability and reliability of the vehicle. This statement supersedes any previously released information by the Chrysler Group LLC. Failure to follow these instructions may result in serious or fatal injury. |
WARNINGS
| WARNING | Use an Occupational Safety and Health Administration (OSHA) approved breathing filter, when spraying paint or solvents in a confined area. Failure to follow these instructions may result in possible serious or fatal injury. avoid prolonged skin contact with petroleum or alcohol based cleaning solvents. do not stand under a hoisted vehicle that is not properly supported on safety stands. Failure to follow these instructions may result in possible serious or fatal injury. |
| CAUTION | When holes are drilled or punched in an inner body panel, verify the depth of space to the outer body panel, electrical wiring or other components. Damage to the vehicle can result. do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result. always have a fire extinguisher ready for use when welding. disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is off. Damage to electrical system can result. do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result. do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break. |
RESTRAINT WARNINGS
| WARNING | To avoid potential physical injury, or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the ORC capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 30 cm (12 in) of an electronic module/harness, then that module/harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens. Failure to follow these instructions may result in serious or fatal injury. |
| WARNING | To avoid serious or fatal injury on vehicles equipped with the Supplemental Restraint System (SRS), never attempt to repair the electrically conductive circuits or wiring components related to the SRS for which there is no MOPAR wiring repair kit. It is important to use ONLY the recommended splicing kit and procedure. For applicable and available MOPAR wiring repair kits, please visit the MOPAR Connector Web Site at the following address on the Internet: (http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can compromise the conductivity and current carrying capacity of those critical electrical circuits, which may cause SRS components not to deploy when required, or to deploy when not required. Only minor cuts or abrasions of wire and terminal insulation where the conductive material has not been damaged, or connector insulators where the integrity of the latching and locking mechanisms have not been compromised may be repaired using appropriate methods. |
| WARNING | To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar® Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. |
| WARNING | To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. |
| WARNING | To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, Occupant Classification System (OCS), seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to follow these instructions may result in accidental airbag deployment. |
| WARNING | To avoid potential physical injury or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the Occupant Restraint Controller (ORC) capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 12 inches (30 centimeters) of an electronic module or wiring harness, then that module or harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens. |
| WARNING | To avoid serious or fatal injury, do not attempt to dismantle an airbag unit or tamper with its inflator. Do not puncture, incinerate or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. An airbag inflator unit may also contain a gas canister pressurized to over 17.24 kPa (2500 psi). Failure to follow these instructions may result in possible serious or fatal injury. |
| WARNING | To avoid serious or fatal injury when handling a seat belt tensioner retractor. Exercise proper care to keep fingers out from under the retractor cover and away from the seat belt webbing where it exits from the retractor cover. Failure to follow these instructions may result in possible serious or fatal injury. |
| WARNING | To avoid serious or fatal injury, replace all Supplemental Restraint System (SRS) components only with parts specified in the Chrysler Mopar® Parts Catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. |
| WARNING | To avoid serious or fatal injury, the fasteners, screws, and bolts originally used for the Supplemental Restraint System (SRS) components must never be replaced with any substitutes. These fasteners have special coatings and are specifically designed for the SRS. Anytime a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the Chrysler Mopar® Parts Catalog. |
| WARNING | To avoid serious or fatal injury when a steering column has an airbag unit attached, never place the column on the floor or any other surface with the steering wheel or airbag unit face down. Failure to follow these instructions may result in possible serious or fatal injury. |
Scheme 93
| 1 - COVER PLATE |
|---|
| 2 - RAIL, REAR, OUTER |
| 3 - RAIL, REAR, INNER |
| 4 - REINFORCEMENT, REAR RAIL INNER, REAR |
"Rail, rear, outer" (2) - this portion of the rear rail assembly is not visible as it is gloved inside the "rail, rear, inner" (3) and the "cover plate, rear rail extension" (1). This rail may not be sectioned!
"Reinforcement, rear rail inner rear" (4) - welded inside of the "rail, rear, inner" (3) and extends from the end of that rail to the "panel, deck opening lower".
Scheme 94
"Rail, rear inner" may be sectioned at this location (1), greatly reducing vehicle disruption and repair costs.
This partial replacement procedure presumes that all damage to the "rail, rear inner" is aft of the crossmember (2).
Left side
Scheme 95
| 1 - HOLE |
|---|
| 2 - 100 mm (4 in.) |
| 3 - REINFORCEMENT, REAR RAIL INNER, REAR |
| 4 - CUT LOCATION 125 mm (5 in.) |
The "Reinforcement, Rear Rail Inner, Rear" (3) ends 100 mm (4 in.) (2) forward of round hole (1) on inner face of "Rail, Rear Inner" - recommended cut location is 125 mm (5 in.) (4) from forward edge of the hole (1).
Right Side
Scheme 96
| 1 - 125 mm (5 in.) |
|---|
| 2 - HOLE |
| 3 - CUT LOCATION 150 mm (6 in.) |
| 4 - REINFORCEMENT, REAR RAIL INNER, REAR |
The "Reinforcement, Rear Rail Inner Rear" (4) ends 125 mm (5 in.) (1) forward of round hole (2) on inner face of "rail, rear inner" - recommended cut location (3) is 150 mm (6 in.) from forward edge of hole (2).
The following procedure details key points of the repair. I-CAR training is presumed, and should be followed for best-practice repair procedures.
- Mount the damaged vehicle onto a structural straightening bench and check/correct any body misalignment utilizing three dimensional measuring equipment.
- Remove all components in area of repair allowing unimpeded access for cutting and welding operations.
- Trunk floor should be removed if being replaced, or the necessary welds released and the weld flange bent inboard to provide access to the rail for the butt-joint.
- Using the round hole in the "Rail, Rear, Inner" as a point of reference, measure 125 mm (5 in.) forward for the left rail, or 150 mm (6 in.) forward for the right rail, and scribe a vertical line on the rail.
- With the vertical line just made as reference, cut off the damaged "Rail, Rear, Inner" taking care not to damage the "Rail, Rear, Outer", using a reciprocating saw or cut-off wheel, and remove the damaged portion.
- Utilize the same measuring and cutting process above to remove the replacement portion from the service part.
- Using a surface conditioning disk, remove all e-coat within 25 mm (1 in.) of the cut location and de-bur the cut edge.
- If the "Rail, Rear, Outer" was damaged during the cutting operation, MIG-weld the damage and dress the weld.
- Fabricate 19 mm (0.75 in.) weld backers from the damaged component, or the remains of the service part, and tack in place on the replacement rail section at the butt-joint location.
- Position and clamp the replacement rail and confirm proper position with measuring equipment.
- Weld the service part in position using a skip-stitch process.
- Complete remaining repairs in the damaged area.
- Clean and dress all welded areas.
- Apply epoxy primer to the exterior of the rail at the repair location.
- Apply quality body sealer to all areas previously sealed to duplicate the original appearance. Note that additional sealer may be applied to better protect the exterior exposed seams from road spray.
- Refinish all exposed surfaces in trunk and on underbody using quality refinish materials.
- Apply inner panel rust proofing, such as Mopar # 05093981AA, or equivalent, to the rail inner cavity areas in two applications with a 30-minute flash period between the applications. Pay particular attention to areas which have been welded.
- Reassemble vehicle and complete repairs.
ADDITIONAL INFORMATION
Observe all cautions and warnings per the Chrysler service manual. Refer to FRAME, WARNING .
Reference the Chrysler weld process chart. Refer to FRAME, SPECIFICATIONS .
Butt joint should be metal finished without thinning the base rail material or weldment. This is a cosmetic finishing process to disguise the repair and should have the surface coating (paint) duplicated as well.
Restore corrosion protection when complete with all welding operations.
WELD PROCESS
| COMPONENT PARTS | TRUCK FRAME | BODYSHELL EXTERIOR & UNDERBODY PANELS | ||||
|---|---|---|---|---|---|---|
| Zinc and Zinc Iron Alloy coated sheet steels | ||||||
| WELDING PROCESS | GAS METAL ARC (Note: 1) | FLUX CORED ARC | GAS METAL ARC (Note: 1) | MIG BRAZE (Note: 2) | GAS METAL ARC (Note: 1) | FLUX CORED ARC |
| Material Type | High Strength and Structural Quality Steels which includes HSLA, Martensitic, and Dual Phase materials | |||||
| Material Thickness Range | 2 mm - 4 mm | 0.6 mm - 1.02 mm | >1.02 mm - 3.0 mm | |||
| ELECTRODE TYPE (AWS SPEC. A5.18) | AWS CLASS. ER70S-6 | AWS CLASS. E71T-11 (Note 3) | AWS CLASS. ER70S-6 | AWS CLASS. ERCuSi - A Silicon Bronze | AWS CLASS. ER70S-6 | AWS CLASS. E71T-11 (Note 3) |
| ELECTRODE SIZE | 0.035 | 0.045 | 0.023 - 0.025 | 0.035 | 0.035 | 0.045 |
| ELECTRODE MAKER | Lincoln® | Lincoln® NR-211-MP | Lincoln® | Lincoln® | Lincoln® NR-211-MP | |
| WIRE FEED SPEED (in/min) | 245-250 Vertical Down | 110 Vertical Down | 95-115 All Welds | 150-155 Flat & Horizontal | 245-250 Vertical Down | 110 Vertical Down |
| 70-90 Flat & Horizontal | 70-90 Flat & Horizontal | 70-90 Flat & Horizontal | 70-90 Flat & Horizontal | |||
| TRAVEL SPEED (in/min) | 10 | |||||
| VOLTAGE | 19-20 | 15-18 | 16-19 | 18-19 | 19-20 | 15-18 |
| POLARITY | DCEP | DCEN | DCEP | DCEP | DCEP | DCEN |
| GAS FLOW (cfh) | 25-35 | N/A | 25-35 | 25-35 | 25-35 | N/A |
| ELECTRICAL STICKOUT (in) | 1/2 - 5/8 | 3/8 - 1/2 | 1/2 - 5/8 | 5/8 - 3/4 | 1/2- 5/8 | 3/8 - 1/2 |
| GAS TYPE | 75% Ar | N/A | 75% Ar | 100% Ar | 75% Ar | N/A |
| 25% CO2 | 25% CO2 | 25% CO2 | ||||
| TYPE OF ARC TRANSFER | Short Circuit | Short Circuit | Pulse | Short Circuit | ||
These Procedure Specifications are appropriate as of this publication. Procedures may be superseded with new spec's at a later date.
Always process to the thinner material thickness (TMT)
All persons performing welding must be qualified to weld in all positions.
Note. Must remove Zinc Coating on both sides of metal at the weld zone. MIG Braze welding process requires use of Pulse Arc® or STT® welding machine. Must use Lincoln® product since E 71T-11 product differs from other suppliers.
FRAME DIMENSIONS
Frame dimensions are listed in metric scale then converted to inch scale listed in parenthesis. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location. Vertical dimensions can be taken from the work surface to the locations indicated.
| DESCRIPTION | FIGURE |
|---|---|
| FRAME DIMENSIONS - BOTTOM VIEW | See scheme 15 |
| FRAME DIMENSIONS - SIDE VIEW | See scheme 16 |
INDEX
