Frame and Bumpers: Removal & Installation Dodge Challenger III рестайлинг

INSTALLATION

1. Place the front air dam into position.
2. Install the air dam mounting fasteners that secure the air dam to the fascia.
3. Install the front fascia. Refer to «FASCIA, FRONT, INSTALLATION»(ref-489280-S41856296312012072600000) .

REMOVAL

1. Remove fascia assembly (9). Refer to «FASCIA, FRONT, REMOVAL»(ref-489280-S09978539662012072600000) .
2. Remove the energy absorber (8) by disengaging the clips (11).
3. Remove the left bumper extension bolt (3) and left bumper extension (7).
4. Remove the right bumper extension bolt (1) and right bumper extension (12).
5. Remove the eight mounting fasteners (4 per side) and remove the bumper (6).

1. Position the bumper (6) and install the eight mounting fasteners (4 per side). Tighten to 28 N.m (21 ft. lbs.).
2. Install the right bumper extension (12) and right bumper extension bolt (1).
3. Install the left bumper extension (7) and left bumper extension bolt (3). Tighten to 28 N.m (21 ft. lbs.).
4. Install the energy absorber (8) by engaging the clips (11).
5. Install the fascia assembly (9). Refer to «FASCIA, FRONT, INSTALLATION»(ref-489280-S41856296312012072600000) .

Scheme 69

1. Remove the rear fascia assembly (4). Refer to «FASCIA, REAR, REMOVAL»(ref-489280-S27551809492012072600000) .
2. Remove the rear energy absorber (7) by disengaging the clips (8).
3. Remove the rear bumper mounting fasteners and remove the bumper (9).

1. Place the bumper into position.
2. Install the mounting fasteners. Tighten to 28 N.m (21 ft. lbs.).
3. Install the rear energy absorber (7) by engaging the clips (8).
4. Install the rear fascia assembly. Refer to «FASCIA, REAR, INSTALLATION»(ref-489280-S32977545272012072600000) .

1. Raise and support the vehicle.
2. Remove the left and right front splash shields as necessary. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-489285-S40885179682012072600000) .
3. Remove the belly pan.
4. Remove the mounting fasteners that secures the front fascia assembly (9) to the inside of the front fender.
5. Partially lower the vehicle and remove the push-pin retainers (10) that secure the front fascia assembly to the upper radiator support.
6. Disconnect the Tire Pressure Monitoring (TPM) connector. Refer to «MODULE, TIRE PRESSURE MONITORING (TPM), REMOVAL»(ref-489281-S25397350232012072600000) .
7. Carefully pull the left and front side of the fascia out of the fender mounted fascia mounting brackets.
8. Carefully pull the front fascia assembly forward to disengage the push-pin retainer from the slot in each side of the fascia and disconnect the fog lamp wire harness connectors, if equipped.

1. Place the front fascia assembly in position and connect the fog lamp wire harness connectors, if equipped.
2. Push the left and front side of the fascia in to the fender mounted fascia mounting brackets.
3. Connect the Tire Pressure Monitoring (TPM) connector.
4. If equipped, connect the headlamp washer system hose from washer reservoir.
5. Raise the vehicle.
6. Install the mounting fasteners that secures the front fascia assembly (9) to the inside of the front fender.
7. Install the belly pan.
8. Install the left and right front splash shields as necessary. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-489285-S03959844982012072600000) .
9. Lower the vehicle.

1. Raise and support the vehicle.
2. Remove the rear splash shields, as necessary. Refer to «SHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL»(ref-489285-S25264909042012072600000) .
3. Remove the left and right rear tail lamps. Refer to «LAMP, TAIL, REMOVAL»(ref-489298-S03223146082012072600000) .
4. Remove the left and right upper fasteners.
5. Remove the lower rear fascia (4) mounting fasteners located under the vehicle.
6. Remove the mounting fasteners in the wheel wells.
7. Remove the upper fascia push pin retainers (6).
8. Carefully pull the left and right side of the rear fascia outward, disengaging the fascia from the fender (2) mounted mounting brackets.
9. Carefully remove the rear fascia from the vehicle and disconnect the electrical connectors.

1. Carefully remove the rear fascia from the vehicle and disconnect the electrical connectors.
2. Carefully pull the left and right side of the rear fascia outward, disengaging the fascia from the fender (2) mounted mounting brackets.
3. Remove the upper fascia push pin retainers (6).
4. Install the mounting fasteners in the wheel wells.
5. Install the lower rear fascia (4) mounting fasteners located under the vehicle.
6. Install the left and right upper fasteners.
7. Install the left and right rear tail lamps. Refer to «LAMP, TAIL, INSTALLATION»(ref-489298-S06083764962012072600000) .
8. Install the rear splash shields, as necessary. Refer to «SHIELD, SPLASH, REAR WHEELHOUSE, INSTALLATION»(ref-489285-S04845698242012072600000) .
9. Lower the vehicle.

Scheme 70

1. Position bushing on crossmember bushing bore aligning bushing can flange (3) with reference marks applied during removal.
2. Assemble tools (See following list) over bushing (3) and crossmember as shown in illustration. (1) Press (special tool #C-4212F, Press, Ball Joint) (2) Receiver (special tool #9031-3, Receiver, Bushing) (4) Installer (special tool #9031-4, Installer, Bushing)
3. Tighten Press (1) screw-drive, pressing bushing into crossmember. Install bushing until bushing can flange contacts surface of crossmember.
4. Remove tools.
5. Verify bushing closely lines up with reference marks applied during removal. NOTE: Do not reinstall coil springs on spring links at this time. Install as directed in later steps.
6. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft (1) onto rear axle differential flange (2) and align shock absorbers with pockets in spring links. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
7. Continue to raise crossmember (1) with jack until crossmember mounting bolts (2 and 3) can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
8. Slowly lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
9. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
10. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
11. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
12. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
13. Raise right side of crossmember (1) into mounted position. Install right side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time.
14. Remove both front and rear crossmember mounting bolts (2 and 3) on left side of vehicle. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
15. Slowly lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
16. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
17. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
18. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
19. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
20. Raise left side of crossmember (1) into mounted position. Install left side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time. 1 - BODY 2 - MARKER (OR CRAYON) 3 - CROSSMEMBER BUSHING FLANGE
21. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
22. Once mounts are lined up with location marks, on both sides of vehicle, measure distance (1) between the tension link (2) and weld flange (3) on body directly in front of it, just outboard of the front mount bushing (4). This distance must be at least 12 mm to allow proper clearance for suspension movement. If distance is less than 12 mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12 mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Remeasure opposite side to be sure it still maintains minimum 12 mm distance.
23. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.).
24. Remove jack (3) from under rear axle differential.
25. Remove bungee cord (1) supporting propeller shaft (2).
26. Align propeller shaft index marks placed upon removal. Install propeller shaft rear coupler-to-axle flange bolts and nuts by hand. Tighten propeller shaft rear coupler-to-axle flange bolts to 81 N.m (60 ft. lbs.).
27. Install fuel filler tube. Refer to «TUBE, FUEL TANK FILLER, INSTALLATION»(ref-489307-S31498133712012072600000) .
28. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
29. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
30. Insert speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.
31. If equipped with standard or premium disc brakes, on each rear disc brake: Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3). CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 31 N.m (23 ft. lbs.) torque. Make sure brake hose is properly routed and will not come in contact with suspension components.
32. If equipped with SRT8 disc brakes, at each rear disc brake, support spring link using a transmission jack or other appropriate jack as indicated in removal procedure. Refer to «CROSSMEMBER, REAR, REMOVAL»(ref-489280-S23643866872012072600000) .
33. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
34. If equipped with SRT8 disc brakes, on each rear disc brake, install caliper mounting bolts (1). Tighten bolts to 130 N.m (96 ft. lbs.) torque.
35. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
36. Route parking brake cable above rear crossmember, then slide cable (1, 3) through equalizer (2) above rear axle differential (once installed). NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
37. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).
38. Insert front parking brake cable routing bracket locating pin into front flange of crossmember (3), then install screw (2) fastening cable (1) routing bracket to rear crossmember.
39. Install rear exhaust system (2) (dual-outlet exhaust shown in illustration).
40. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.). Refer to «INSTALLATION»(ref-489281-S31552247222012072600000) .
41. Lower vehicle until rear wheels are just above floor level.
42. Apply parking brake lever. Release lever, then reapply.
43. Check to make sure rear wheels will not rotate with lever applied.
44. Lower vehicle.
45. Connect the battery negative cable (2) to the battery post.
46. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
47. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
48. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft. lbs.).
49. Perform wheel alignment, paying special attention to thrust angle. If rear crossmember needs to be shifted to align thrust angle, try to avoid compromising tension link clearance. Refer to 22 and «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-489278-S17595379302012072600000) .

Scheme 71

Scheme 72

1. Raise and support vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-489279-S05318852982012072600000) .
2. Access and remove rear spring on side of repair. Refer to «REMOVAL»(ref-489287-S31881445852012072600000) .
3. Export Only - If servicing right side bushing, disconnect headlamp leveling sensor (1) link at spring link (3).
4. Remove bolt and nut (1) fastening spring link (4) to crossmember.
5. Position spring link downward, away from bushing in crossmember. 1 - BUSHING 2 - REMOVER 9032-2 3 - PRESS C-4212F 4 - RECEIVER 9032-1 NOTE: Prior to using Press (3), Special Tool (special tool #C-4212F, Press, Ball Joint), lubricate screw-drive threads to provide ease of use and promote tool longevity.
6. Assemble tools over bushing as shown in illustration (See list). Ensure Receiver, Special Tool (special tool #9032-1, Receiver, Bushing), sets against crossmember and not welds. (2) Remover (special tool #9032-2, Receiver, Bushing) (3) Press (special tool #C-4212F, Press, Ball Joint) (4) Receiver (special tool #9032-1, Receiver, Bushing)
7. Tighten Press screw-drive, pressing bushing out of crossmember.

Scheme 73

1. Position bushing (1) over rear of crossmember bushing bore.
2. Assemble tools over bushing and crossmember as shown in illustration (See list). Ensure Receiver, Special Tool (special tool #9032-3, Pusher, Bushing), is positioned to avoid welds on rear of crossmember bushing bore. (2) Remover/Installer (special tool #9032-2, Receiver, Bushing) (3) Press (special tool #C-4212F, Press, Ball Joint) (4) Receiver (special tool #9032-3, Pusher, Bushing)
3. Tighten Press screw-drive, pressing bushing into crossmember. Install bushing until screw-drive stops, when bushing contacts Receiver on opposite side of crossmember.
4. Remove tools.
5. Swing spring link up to bushing in crossmember and install bolt and nut (1) fastening spring link (4) to crossmember. Do not tighten bolt at this time.
6. Export Only - If servicing right side bushing, connect headlamp leveling sensor (1) link at spring link (3).
7. Install rear spring as well as all components necessary to access it. Refer to «INSTALLATION»(ref-489287-S37394151262012072600000) .
8. Lower vehicle.
9. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolt.
10. Tighten spring link bolt (1) at crossmember to 108 N.m (80 ft. lbs.).
11. Perform wheel alignment. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-489278-S17595379302012072600000) .

Scheme 74

Scheme 75

1. Raise and support the vehicle.
2. Remove the fasteners that secure the front belly pan to the front fascia.
3. Remove the fasteners (2) that secure the front belly pan (1) to the underside of the vehicle.
4. Remove the push pins that connect the front belly pan to the front splash shields.
5. Remove the front belly pan from the underside of the vehicle.
6. Remove the fasteners (1) that secure the rear belly pan (2) to the underside of the vehicle.
7. Remove the rear belly pan from the underside of the vehicle.

Note. During installation, ensure rear belly pan is shingled underneath front belly pan. Failure to do so may result in damage to belly pan.

1. Position the rear belly pan (2) to the underside of the vehicle.
2. Install the fasteners (1) that secure the rear belly pan to the underside of the vehicle.
3. Position the front belly pan (1) to the underside of the vehicle.
4. Install the fasteners (2) that secure the front belly pan to the underside of the vehicle.
5. Install the fasteners that secure the front belly pan to the front fascia.
6. Install the push pins that connect the front belly pan to the front splash shields.
7. Lower the vehicle.