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Home/Dodge/Dakota/Dodge Dakota III рестайлинг (2007-2011)/Repair manual/Frames, Subframes & Crossmembers/Frame and Bumpers: Other
Contents Section: Frames, Subframes & Crossmembers All sections

Frame and Bumpers: Other Dodge Dakota III рестайлинг

Frames, Subframes & Crossmembers 11 illustrations ~1151 words

USE OF HEAT DURING REPAIR

WARNINGChrysler 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.

SAFETY PRECAUTIONS AND WARNINGS

WARNINGBefore performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the airbag control module (acm). Failure to take the proper precautions could result in accidental airbag deployment and other possible damage to the supplemental restraint system circuits and components. Use eye protection when grinding or welding metal, serious eye injury can result. Before proceeding with frame repair involving grinding or welding, verify that vehicle fuel system is not leaking or in contact with repair area, personal injury can result. Do not allow open flame or heat and metal spatter from arc welding, to contact plastic body panels. Fire or explosion can result. When welded frame components are replaced, ensure complete penetration weld is achieved during installation. If not, dangerous operating conditions can result. Stand clear of cables or chains on pulling equipment during frame straightening operations, personal injury can result. Do not venture under a hoisted vehicle that is not supported on safety stands, personal injury can result. No heat may be used if frame straightening is required. The use of heat is acceptable in those situations where the part being heated will be replaced. Failure to follow these instructions may result in personal injury.
CAUTIONDo not reuse damaged fasteners, quality of repair would be suspect. Failure to use only production fasteners or fasteners of equivalent hardness can result in loosening or failure. Do not drill any holes in the frame that are not specifically outlined in this or other Chrysler procedures as frame rail failure can result.

HYDROFORM FENDER RAIL REPAIR

CAUTIONThis repair procedure assumes damage to the right or left hydroform fender rail. Prior to any repairs, the vehicle must be mounted on the appropriate frame repair equipment ("frame rack"), checked with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional corrections are made, the hydroform must be replaced in its entirety. Refer to Body/Body Structure/Weld Locations - Specifications , when replacing the entire hydroform.
CAUTIONInspect the tire winch assembly for damage. If any one or more of the following are evident, replace the winch assembly. Indications of cracked or bulging plastic. Housing flanges are bent or cracked. If winch was loose before repair. If the rivet heads are separated from the housing in any way.

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  1. Before proceeding with this repair procedure review the required service warnings and precautions. See «Frame and Bumpers/Frame - Warning»(ref-352663-S41122896432010010600000)
  2. Disconnect and isolate the battery negative cable.
  3. Remove the front wheelhouse splash shield. Refer to «Body/Exterior/SHIELD, Splash - Removal»(ref-352624-S15760575692010010600000)
  4. Remove the fender. Refer to «Body/Exterior/FENDER, Front - Removal»(ref-352624-S00068936922010010600000)
  5. Remove the A/C condenser, if required. Refer to «Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Removal»(ref-352632-S24313892522010010600000)
  6. Remove the A/C lines, if required. Refer to the appropriate HEATING AND AIR CONDITIONING article for recommended procedures.
  7. Remove the radiator assembly. Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Removal»(ref-352638-S08636206802010010600000)
  8. Remove the air cleaner and support bracket, if required. Refer to «Engine/Air Intake System/AIR CLEANER - Removal»(ref-352641-S00498279112010010600000)
  9. Remove the integrated power module. Refer to «Electrical - Wiring/Power Distribution/MODULE, Integrated Power (IPM) - Removal»(ref-352650-S02626081702010010600000) .
  10. Remove the bolts and position aside the wire harness and grounds, if required.
  11. Remove the upper radiator crossmember. Refer to «Body/Exterior/CROSSMEMBER, Radiator - Removal»(ref-352624-S33133076582010010600000)
  12. Remove the headlamp unit. Refer to «Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/UNIT, Front Lamp - Removal»(ref-352634-S03755301302010010600000)
  13. Remove the front cab mount to the Front End Sheet Metal bracket (FESM) bolt.
  14. Remove the bolts attaching the lower radiator crossmember to the hydroform fender rail. CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal characteristics and may weaken the frame and/or repair location.
  15. Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the hydroform and remove.
  16. Smooth and square the cut edges.
  17. Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth and square the cut edges. NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle geometry. 1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - CENTER LINE 5 - LOCATOR LINES (2) 6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.) (BOTH FRAME SECTIONS) 7 - LOCATOR LINE DIMENSION - 2 mm (0.08 in.) 8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.) (BOTH FRAME SECTIONS) 9 - RING FILLET WELD HOLES
  18. Fabricate 51 mm (2.0 in.) long repair inserts (5) using scrap from the old structure or the replacement part. It will be necessary to split the inserts on each of their four sides to fit into the hydroform.
  19. Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydroforms.
  20. Cut plug weld holes (1) as described below. On the upper rail, cut one 13 mm (0.5 in.) hole (1) on each side of the rail, 25 mm (1.0 in.) from the butt joint of the tube (4). On the lower rail, cut one 13 mm (0.5 in.) hole (1) on the top and bottom sides of the rail 25 mm (1.0 in.) from the butt joint of the tube (4). On the lower rail, cut two 13 mm (0.5 in.) holes (1) on the inner and outer sides of the rail 25 mm (1.0 in.) from the butt joint of the tube (4). CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
  21. Install the insert (2) 1" into the replacement part (6) and tack into place with a weld. See «Frame and Bumpers/Frame - Specifications»(ref-352663-S10509370902010010600000)
  22. Insert the service part into place and using the appropriate measuring equipment, verify the front end sheet metal bracket's location in all three (X,Y, and Z) planes of space.
  23. Complete all 360° plug welds. NOTE: Before the final welding, use three dimensional measuring equipment to ensure the part is in the correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward shotgun ends.
  24. Complete welding by making a 360° butt weld around the fender rails.
  25. Metal finish the exposed welds on the hydroforms.
  26. Dress the welded area and apply corrosion resistant coatings inside and out. Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydroforms ensuring 100% coverage including the mating face between the fender rail sections and insert such that corrosion protection is restored in the internal cavity. Apply a durable top coat to the outside of the repair area.
  27. Install the front body mount bolt if previously removed and tighten to 81 N.m (60 ft. lbs.).
  28. Install the lower radiator crossmember bolts and tighten to 28 N.m (21 ft. lbs.).
  29. Install the headlamp unit. Refer to «Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/UNIT, Front Lamp - Installation»(ref-352634-S37544626372010010600000)
  30. Install the upper radiator crossmember. Refer to «Body/Exterior/CROSSMEMBER, Radiator - Installation»(ref-352624-S26711416632010010600000)
  31. Install the wire harness and ground if previously removed and install the bolts.
  32. Install the integrated power module, if previously removed. Refer to «Electrical - Wiring/Power Distribution/MODULE, Integrated Power (IPM) - Installation»(ref-352650-S31638069892010010600000) .
  33. Install the air cleaner bracket and air cleaner, if previously removed. Refer to «Engine/Air Intake System/AIR CLEANER - Installation»(ref-352641-S23766367912010010600000)
  34. Install the radiator assembly. Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Installation»(ref-352638-S42532203632010010600000)
  35. Install the A/C lines, if previously removed. Refer to the appropriate HEATING AND AIR CONDITIONING article for the recommended procedures.
  36. Install the A/C condenser, if previously removed. Refer to «Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Installation»(ref-352632-S10718663932010010600000)
  37. Install the fender. Refer to «Body/Exterior/FENDER, Front - Installation»(ref-352624-S37923409252010010600000)
  38. Install the front wheelhouse splash shield. Refer to «Body/Exterior/SHIELD, Splash - Installation»(ref-352624-S01933160122010010600000)
  39. Reconnect the battery ground.

WELD PROCESS

CAUTIONAll welds should conform to the Chrysler LLC vehicle engineering process standard PS 9472.
WELDING PROCESSFLUX CORED ARCGAS METAL ARC (MIG)*SHIELDED METAL ARC (STICK)
Material Thickness3.7 mm to 4.2 mm3.7 mm to 4.2 mm3.7 mm to 4.2 mm
Electrode TypeLincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute)AWS ER70S-3 (Do Not Substitute)** AWS E 7018
Electrodes Size Inches045 Tubular035 Solid3/32"
Electrode Stick Out3/8" - 1/2"1/2" - 5/8"N/A
PolarityElectrode "-" Work Piece "+"Electrode "+" Work Piece "-"Electrode "+" Work Piece "-"
Shielding GasSelf Shielded75% Ar 25% CO2Self Shielded
Gas Flow RateN/A25 - 35 CFMN/A
Wire Feed Speed (inches per minute)110 - 130 Vertical Down 70 - 90 Flat AND Overhead245 - 250 Vertical Down 210 - 225 Flat AND OverheadN/A
Approximate Amperage
Vertical110 - 13017585 (3/32" Diameter)
Flat AND Overhead70 - 9015590 (3/32" Diameter)
Voltage15 - 1819 - 20N/A
Direction of Welding
VerticalVertical Down Hill (only)Vertical Down Hill (only)Vertical - Up Hill (only)
Flat AND OverheadFlat - Push or DragFlat - Push or DragFlat - Drag

WELDING PARAMETERS

*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass should only fill approximately 1/2 the thickness. Vertical position welds - maintain electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for FCAW as well.

**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect. Reconditioning schedules should come from the manufacturer.

FRAME DIMENSIONS

Frame dimensions are listed in metric scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location.

VEHICLE PREPARATION

Position the vehicle on a frame alignment rack, refer to instructions provided with equipment being used. Adjust the vehicle PLP heights to the specified dimension above the work surface (datum line). Vertical dimensions can be taken from the datum line to the locations indicated were applicable.

DESCRIPTIONFIGURE
ND 33 TOP VIEW - (4 X 2)(Scheme 25)
ND 33 LEFT SIDE VIEW - (4 X 2)(Scheme 26)
ND 33 TOP VIEW - (4 X 4)(Scheme 27)
ND 33 LEFT SIDE VIEW - (4 X 4)(Scheme 28)
ND 84 TOP VIEW - (4 X 2)(Scheme 29)
ND 84 LEFT SIDE VIEW - (4 X 2)(Scheme 30)
ND 84 TOP VIEW - (4 X 4)(Scheme 31)
ND 84 LEFT SIDE VIEW - (4 X 4)(Scheme 32)

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Scheme 28

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Scheme 29

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Scheme 33: REMOVAL
Scheme 33: REMOVAL
  1. Lift and support the vehicle.
  2. Remove the four bolts (2) and nuts (1), and remove the crossmember.

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