Frame and Bumpers: Removal & Installation Dodge Charger VI

INSTALLATION

Note. 300 Shown in illustration. Magnum and Charger similar.

1. Position the bumper. NOTE: It is not necessary to spot weld the bumper back into place.
2. Install the bolts and tighten to 28 N.m (21 ft. lbs.).
3. Install the fascia. Refer to «FASCIA, FRONT, INSTALLATION»(ref-481393-S25865678362012062200000) .

Scheme 71

Note. 300 Shown in illustration. Magnum and Charger similar.

1. Remove the fascia assembly. Refer to «FASCIA, REAR, REMOVAL»(ref-481393-S23402417692012062200000) .
2. Remove the six nuts and washers and remove the bumper.

1. Position the bumper.
2. Install the nuts and washers and tighten to 28 N.m (21 ft. lbs.).
3. Install the fascia assembly. Refer to «FASCIA, REAR, INSTALLATION»(ref-481393-S19569189572012062200000) .

Scheme 72

Note. Base model Shown in illustration, SRT models similar.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the fastener (1) that secure the front fascia assembly to the fender.
4. Remove the three fasteners (2) that secure each front wheel house splash shield to the front fascia assembly.
5. Repeat the removal steps for the opposite side.
6. Remove the rear belly pan (1). Refer to «BELLY PAN, REMOVAL»(ref-481393-S12540850292012062200000) .
7. Remove the front belly pan (2). Refer to «BELLY PAN, REMOVAL»(ref-481393-S12540850292012062200000) .
8. If equipped, disconnect the harness (2) from the fog lamps (1). Repeat on the opposite side.
9. Lower the vehicle.
10. Remove the upper radiator deflectors (1).
11. Pull out on the fascia (1) at the wheel house opening to disengage the fascia from the fender retaining bracket. Repeat on the opposite side.
12. Remove the four fascia to radiator support fasteners (1).
13. With the help of an assistant, remove the fascia (2) from the vehicle.

Note. Base model Shown in illustration, SRT models similar.

1. With the help of an assistant, position the fascia (2) to the vehicle.
2. Install the four fascia to radiator support fasteners (1).
3. Align the retaining tabs on the fascia (1) with the fender retaining bracket located between the bottom corner of the headlamp and the lower front corner of the fender.
4. Once aligned, firmly hand tap the fascia (1) to engage the retaining tabs.
5. Install the upper radiator deflectors (1).
6. Raise and support the vehicle.
7. If equipped, connect the harness (2) to the fog lamps (1).
8. Install the front belly pan (2). Refer to «BELLY PAN, INSTALLATION»(ref-481393-S23976762282012062200000) .
9. Install the rear belly pan (1). Refer to «BELLY PAN, INSTALLATION»(ref-481393-S23976762282012062200000) .
10. Install the three fasteners (2) that secure each front wheel house splash shield to the front fascia assembly.
11. Install the fastener (1) that secure the front fascia assembly to the fender. Tighten the fastener securely.
12. Lower the vehicle.
13. Connect the negative battery cable.

Scheme 79

Note. Base model Shown in illustration, SRT models similar.

Scheme 80

Scheme 81

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the three push-pin retainers (2) that secure each rear wheel house splash shield to the rear fascia assembly.
4. Remove the fastener (1) that secures the rear fascia assembly to the rear quarter.
5. Remove the fastener (3) that secures the rear fascia assembly to the rear fascia support bracket.
6. Repeat the removal steps on the opposite side.
7. Remove the tail lamp. Refer to «LAMP, TAIL STOP TURN, REMOVAL»(ref-481413-S32451788142012062200000) . Repeat on opposite side.
8. Remove the fastener (1) located in the tail lamp cavity that secures the fascia (2) to the rear quarter. Repeat for opposite side.
9. Pull out on the fascia (2) at the wheel house opening to disengage the fascia from the retaining bracket. Repeat on the opposite side.
10. With the help of an assistant, pull rearward to disengage the fascia (1) from the rear retaining bracket. Do not completely remove at this time.
11. Disconnect the vehicle wiring harness.
12. With the help of an assistant, remove the fascia (1) from the vehicle.

Note. Base model Shown in illustration, SRT models similar.

1. With the help of an assistant, position the fascia (2) to the vehicle.
2. Connect the vehicle wiring harness.
3. With the help of an assistant and using firm pressure, align and push forward to engage the fascia to the rear retaining bracket.
4. Install the fastener (1) located in the tail lamp cavity that secures the fascia (2) to the rear quarter. Tighten the fastener securely. Repeat for opposite side.
5. Align the fascia (2) with the retaining bracket and using firm pressure push in to engage. Repeat on the opposite side.
6. Install the tail lamp. Refer to «LAMP, TAIL STOP TURN, INSTALLATION»(ref-481413-S15873314982012062200000) . Repeat on opposite side.
7. Install the three push-pin retainers (2) that secure each rear wheel house splash shield to the rear fascia assembly. Repeat for opposite side.
8. Install the fastener (1) that secures the rear fascia assembly to the rear quarter. Tighten the fastener securely. Repeat for opposite side.
9. Install the fastener (3) that secures the rear fascia assembly to the rear fascia support bracket. Tighten the fastener securely. Repeat for opposite side.
10. Connect the negative battery cable.

Scheme 82

1. Position bushing on crossmember bushing bore aligning bushing can flange (3) with reference marks applied during removal.
2. Assemble tools (refer to 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-481421-S09724163252012062200000) .
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 «ISOLATOR, REAR CROSSMEMBER, DIFFERENTIAL, REMOVAL»(ref-481393-S12725635752012062200000) and «ISOLATOR, REAR CROSSMEMBER, FRONT MOUNT, REMOVAL»(ref-481393-S04416490082012062200000) and «ISOLATOR, REAR CROSSMEMBER, REAR MOUNT, REMOVAL»(ref-481393-S27796058052012062200000) and «ISOLATOR, REAR CROSSMEMBER, SPRING LINK, REMOVAL»(ref-481393-S29762526602012062200000) .
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-481394-S17314576732012062200000) .
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 battery negative cable (2) to 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-481391-S31500006042012062200000) .

Scheme 83

Scheme 84

1. Raise and support vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-481392-S03705606742012062200000) .
2. Access and remove rear spring on side of repair. Refer to «SPRING(S), REMOVAL»(ref-481400-S18010910832012062200000) .
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 (refer to 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 85

1. Position bushing (1) over rear of crossmember bushing bore.
2. Assemble tools over bushing and crossmember as Shown in illustration (refer to 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 «SPRING(S), INSTALLATION»(ref-481400-S14545291492012062200000) .
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-481391-S31500006042012062200000) .

Scheme 86

Note. Base model Shown in illustration, SRT models similar.

1. Raise and support the vehicle.
2. Remove the four fasteners (2) that secure the rear belly pan (1) to the underside of the vehicle.
3. Pull the rear belly pan (1) rearward out of the from the front belly pan (3) to remove from the vehicle.
4. Remove the six screws (4) that secure the front belly pan (2) to the underside of the vehicle's front fascia.
5. Remove the three screws (1) that secure the front belly pan (2) to the underside of the vehicle's wheelhouse inner. Repeat for the other side.
6. Remove the four push pin fasteners (3) that secure the front belly pan (2) to the underside of the vehicle's lower crossmember. Repeat for the other side.
7. Remove the front belly pan (2) from the underside of the vehicle.

Note. Base model Shown in illustration, SRT models similar.

1. Position the front belly pan (2) to the underside of the vehicle.
2. Install the four push pin fasteners (3) that secure the front belly pan (2) to the underside of the vehicle's lower crossmember.
3. Install the six screws (4) that secure the front belly pan (2) to the underside of the vehicle's front fascia.
4. Install the three screws (1) that secure the front belly pan (2) to the underside of the vehicle's wheelhouse inner. Tighten the screws securely. Repeat for the other side. NOTE: During installation, ensure rear belly pan is shingled underneath front belly pan. Failure to do so may result in damage to belly pan.
5. Position the rear belly pan (1) to the underside of the vehicle and to the front fascia (3).
6. Install the fasteners (2) that secure the rear belly pan (1) to the underside of the vehicle. Tighten the fasteners securely.
7. Lower the vehicle.

Scheme 87

Note. Right side Shown in illustration, left side typical.

1. Raise and support the vehicle.
2. Remove the two fasteners (3) that secure the underbody shield (1) to the rear wheelhouse splash shield.
3. Remove the six retaining nuts (2) that secure the underbody shield (1) to the vehicle underbody.
4. Remove the underbody shield from the vehicle.

Note. Right side Shown in illustration, left side typical.

1. Position the underbody shield (1) to the vehicle.
2. Install the six retaining nuts (2) that secure the underbody shield (1) to the vehicle underbody. Tighten the nuts securely.
3. Install the two fasteners (3) that secure the underbody shield (1) to the rear wheelhouse splash shield.
4. Lower the vehicle.

Scheme 88

1. Raise and support the vehicle.
2. Remove the three retaining nuts (2) that secure the rear underbody shield/panel (1) to the tire tub area located forward of the rear fascia.
3. Remove the rear underbody shield/panel (1) from the vehicle.

1. Position the rear underbody shield/panel (1) to the vehicle.
2. Install the three retaining nuts (2) that secure the underbody shield (1) to the vehicle underbody. Tighten the nuts securely.
3. Lower the vehicle.