Frame and Bumpers: Removal & Installation Dodge Dakota III рестайлинг

INSTALLATION

1. Install the fascia support (4) and install the right (1) and left (3) nuts.
2. Tighten the nuts to 95 N.m (70 ft. lbs.).
3. Install the fascia support bracket. See «Frame and Bumpers/Bumpers/BRACKET, Fascia Support - Installation»(ref-352663-S18296179652010010600000)
4. Check front fascia gap and flush positioning. Refer to «Body/Body Structure/Gap and Flush - Specifications»(ref-352624-S28210567652010010600000)
5. Loosen the nuts (1 and 3) and adjust the front fascia to specifications.
6. Tighten the nuts to 95 N.m (70 ft. lbs.).

Scheme 2

1. Disconnect the license plate lamp electrical connectors and separate the wire harness from the bumper (2).
2. Support the bumper (2).
3. Remove the four nuts (4) attaching the bumper (2) to the hitch (3).
4. Remove the bumper.

1. Verify that the stud plates (1) are in place and install the bumper (2) onto the trailer hitch (3) brackets.
2. Install the nuts (4) and adjust the bumper gap to specifications. Refer to «Body/Body Structure/Gap and Flush - Specifications»(ref-352624-S28210567652010010600000)
3. Tighten the nuts to 54 N.m (40 ft. lbs.).
4. Position the license plate light wire harness back onto the bumper and connect the electrical connectors.

Scheme 3

Scheme 4

1. Remove the wheel well screws (2) on each side of the vehicle.
2. Remove the upper three screws (2).
3. Remove the two push pins on the lower edge and remove the fascia (3).

1. Position the fascia (3) onto the support bracket (1).
2. Install the three upper screws (2).
3. Install the two lower edge push pin fasteners.
4. Install the three screws (2) at each wheel well.

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1. Remove the fascia. See «Frame and Bumpers/Bumpers/FASCIA, Front - Removal»(ref-352663-S41727374382010010600000)
2. Remove the three screws on the top of the bracket (2).
3. Remove the six screws (3) and separate the bracket (2) from the fascia support (1).
4. Disconnect the fog lamp electrical connector (2).
5. Remove the fog lamp (3) from the bracket (4).

1. Install the fog lamps (3) onto the bracket (4) and position the bracket onto the vehicle (1).
2. Connect the fog lamp electrical connector (2).
3. Install the three screws on the top of the bracket (2).
4. Install the three screws (3) on each side of the bracket (2).
5. Install the fascia. See «Frame and Bumpers/Bumpers/FASCIA, Front - Installation»(ref-352663-S15779874802010010600000)

FRONT FRAME RAIL TIP REPLACEMENT

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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 (4).
3. Remove the front fender liner of the side being serviced. Refer to «Body/Exterior/SHIELD, Splash - Removal»(ref-352624-S15760575692010010600000) .
4. Remove the front fascia support (4). See «Frame and Bumpers/Bumpers/BRACKET, Fascia Support - Removal»(ref-352663-S16178330142010010600000)
5. Remove the washer bottle and coolant recover bottles, if required.
6. Remove the radiator and lower radiator hose. Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Removal»(ref-352638-S08636206802010010600000)
7. Remove the sway bar mounting bracket bolts (1) and position the sway bar (2) out of the way.
8. For left side frame rail tips, position the power steering hoses (2) and axle vent hose (1), out of the way.
9. Remove the front structure mount bolt (3) to the Front End Sheet Metal (FESM) bracket and the lower bumper support nuts (1) attaching the tow hook (5), if equipped. CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in the next step. This is due to the inaccurate nature of the cut-line and the fact that the high temperatures achieved during the flame or plasma cutting will change the metal characteristics and may weaken the frame and/or repair location. NOTE: Durango shown in illustration, Dakota similar.
10. Using a reciprocating saw (2) or equivalent, carefully cut and remove the damaged frame rail tip behind the stop bracket (1).
11. Remove the three puddle welds attaching the remaining frame tip section (2) to the frame (1) at the locations indicated. (Right side shown in illustration, left side similar.) NOTE: Durango shown in illustration, Dakota similar.
12. Remove the welds (4) by cutting along the outside edge of the weld (1) approximately 1/8 in. (2) using a plasma cutter or drilling out and then using a grinder to remove the welds. CAUTION: Oxyacetylene cutting torches or equivalent flame sources should never be used for cutting or welding. Only non-flame cutting methods should be used unless specified otherwise. NOTE: Durango shown in illustration, Dakota similar.
13. With the puddle welds (1) removed, remove the remaining piece of the frame tip (2) from within the frame rail and discard.
14. Smooth and square the cut edges of the original frame.
15. Remove any burrs at the holes (1) and frame edges. NOTE: Durango shown in illustration, Dakota similar.
16. Dry fit the new rail (2) to verify alignment, fit and make any adjustments as necessary.
17. Remove all internal and external OEM e-coat within 25 mm (1.0 in.) of the weld joint on the replacement tip and the existing frame rail. NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings. CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
18. Loosely install the lower FESM insulator and front structure mounting bolt (3). NOTE: Durango shown in illustration, Dakota similar.
19. Position the stop bracket (2) against the frame rail (1).
20. Using the appropriate measuring equipment, verify the front end sheet metal bracket's location in all three (X,Y, and Z) planes of space, and adjust if required. See «Frame and Bumpers/Frame - Specifications»(ref-352663-S10509370902010010600000) CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat. NOTE: Durango shown in illustration, Dakota similar.
21. When correctly fitted, tack the three upper ring fillet welds (1) to hold the tip (3) in position, then complete the ring fillet welds (1). NOTE: Ring-fillet welds may be filled in with weld material if an improved cosmetic appearance is desired.
22. Confirm alignment of the replacement frame rail tip.
23. Final welding should be performed in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the Weld Process Specifications at the end of this Service Information . The preferred method is GMAW (MIG). See «Frame and Bumpers/Frame - Specifications»(ref-352663-S10509370902010010600000) Apply root pass welds to the root joint (5) behind the stop bracket (2), one quadrant at a time, switching to the opposite side of the frame for each quadrant. Apply root pass welds to the root joint in front (4) of the stop bracket (2), one quadrant at a time, switching to the opposite side of the frame for each quadrant. Clean the welds of any flux and other impurities before proceeding with the cover pass welds. Apply the cover pass welds in the same manner as described above.
24. Confirm alignment of the replacement frame rail tip. NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings.
25. Dress the welded area and apply corrosion resistant coatings inside and out. Apply etch-primer to the inside of the frame rail repair area. Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the space between the original frame rail and the reinforcing sleeve. Apply a durable top coat to the outside of the repair area.
26. Install the tow hook assembly (5), if equipped, and install the two lower fascia support nuts (1).
27. Tighten the nuts (1) to 95 N.m (70 ft. lbs.).
28. Install the front body mount bolt (3) and tighten to 81 N.m (60 ft. lbs.).
29. Install the front fascia support (4). See «Frame and Bumpers/Bumpers/BRACKET, Fascia Support - Installation»(ref-352663-S18296179652010010600000)
30. Position the stabilizer bar (2) back and install the support bracket bolts (1).
31. Tighten the bracket bolts (1) to the frame to 61 N.m (45 ft. lbs.).
32. Position the power steering lines (2) and the axle vent tube (1) back into possition, if necessary.
33. Install the radiator and lower radiator hose. Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Installation»(ref-352638-S42532203632010010600000)
34. Install the front fender liner. Refer to «Body/Exterior/SHIELD, Splash - Installation»(ref-352624-S01933160122010010600000) .
35. Connect the negative battery cable (4).

1. Install the crossmember (3) and install the bolts (2) and nuts (1).
2. Tighten the bolts and nuts to 102 N.m (75 ft. lbs.).

Scheme 21

1. Remove the bumper. See «Frame and Bumpers/Bumpers/BUMPER, Rear - Removal»(ref-352663-S32774127682010010600000)
2. Disconnect the trailer wiring electrical connectors.
3. Remove the bolts (1) and remove the hitch (2).

1. Install the hitch (2) and install the bolts (1).
2. Tighten the bolts to 170 N.m (125 ft. lbs.).
3. Connect the trailer wiring electrical connectors.
4. Install the bumper. See «Frame and Bumpers/Bumpers/BUMPER, Rear - Installation»(ref-352663-S35122354762010010600000)

Scheme 22

1. Remove the Front End Sheet Metal (FESM) mounting bolt (3).
2. Remove the two lower fascia support nuts (1) and remove the tow hook assembly (5).
3. Remove the nuts (3) and remove the brackets (1 AND 2).

1. Install the brackets (1 AND 2) and install the nuts (3).
2. Tighten the nuts to 95 N.m (70 ft. lbs.).
3. Install the hook assembly (5) and install the FESM bolt (3).
4. Install the fascia support nuts (1).
5. Tighten the FESM Bolt (3) to 75 N.m (55 ft. lbs.).
6. Tighten the fascia support nuts (1) to 95 N.m (70 ft. lbs.).