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Contents Section: Frames, Subframes & Crossmembers All sections

Frame & Bumpers: Other Dodge Durango II рестайлинг

Frames, Subframes & Crossmembers 15 illustrations ~1638 words

FASCIA-FRONT

  1. Place the upper edge of fascia (1) onto the center support bracket under the grille and push on to snap retainers (2) together.
  2. Insert the retainer pins (3) on the ends of the fascia into the holes in the lower fender flanges.
  3. Install the screws (5).
  4. Connect the fog lamp electrical connectors (6).
  5. Install the screws (1).
  6. Install the screws (2).
  7. Install the wheel liner screws.

Scheme 28

Scheme 28: SUPPORT-FRONT FASCIA
Scheme 28: SUPPORT-FRONT FASCIA

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Remove the front fascia. See «REMOVAL»(ref-285325-S10450755402008052100000) .
  2. Remove the front bolts next to the fog lights.
  3. Disconnect the fog lamp electrical connectors, if equipped.
  4. Release the tabs and remove the bumper.
  5. Remove the fog lamps from the bumper as necessary. Refer to «REMOVAL»(ref-285329-S10009528112008052100000) .

SUPPORT-FRONT FASCIA

  1. Install the fog lamps into the bumper, if necessary. Refer to «INSTALLATION»(ref-285329-S13640401352008052100000) .
  2. Position the bumper onto the bumper support and seat the tabs fully.
  3. Connect the fog lamp electrical connectors, if equipped.
  4. Install the front bolts next to the fog lamps.
  5. Install the fascia. See «INSTALLATION»(ref-285325-S24283484052008052100000) .

Scheme 31

Scheme 31: BUMPER-FRONT
Scheme 31: BUMPER-FRONT
  1. Remove the bumper. See «REMOVAL»(ref-285325-S18272920092008052100000) .
  2. Remove the eight nuts (2) and remove the bumper reinforcement (1).

BUMPER-FRONT

  1. Install the bumper support (1) and install the nuts (2).
  2. Tighten the nuts to 109 N.m (80 ft. lbs.).
  3. Install the front bumper. See «INSTALLATION»(ref-285325-S37048263902008052100000) .

Scheme 32

Scheme 32: FASCIA-REAR
Scheme 32: FASCIA-REAR

Scheme 33

Scheme 33
Scheme 33
  1. Raise and support the vehicle.
  2. Remove the screws (1) securing the fascia to the support brackets (2).
  3. Remove the lower push pin fasteners (5).
  4. Open the liftgate and remove the upper push pin fasteners (2).
  5. Remove the fascia (3).

FASCIA-REAR

  1. Position the fascia (3) and install the push pin fasteners (2).
  2. Install the lower push pin fasteners (5).
  3. Install the screws (1) securing the fascia to the support brackets (2).

Scheme 34

Scheme 34: SUPPORT-REAR BUMPER
Scheme 34: SUPPORT-REAR BUMPER
  1. Remove the rear fascia. See «REMOVAL»(ref-285325-S14001970872008052100000) .
  2. Remove the rivets (3) and remove the foam bumper support.

SUPPORT-REAR BUMPER

  1. Position the foam support (2) and install new rivets (3).
  2. Install the rear fascia. See «INSTALLATION»(ref-285325-S18312972422008052100000) .

Scheme 35

Scheme 35: BRACKET-REAR FASCIA
Scheme 35: BRACKET-REAR FASCIA
  1. Remove the fascia. See «REMOVAL»(ref-285325-S14001970872008052100000) .
  2. Remove the bolts (1), (2) and (5) and remove the brackets (3) and (4).

BRACKET-REAR FASCIA

  1. Install the brackets (3) and (4) and install the bolts (1), (2) and (5).
  2. Install the fascia. See «INSTALLATION»(ref-285325-S18312972422008052100000) .

WARNING - FRAME REPAIR

WARNINGBefore performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the Occupant Restraint Controller (ORC). 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, DaimlerChrysler procedure 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 SPECIFICATIONS .
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.

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Before proceeding with this repair procedure review the required service warnings and precautions. See «WARNING»(ref-285325-S23339964732008052100000) .
  2. Disconnect and isolate the battery negative cable.
  3. Remove the front fender liner. Refer to «DESCRIPTION»(ref-285328-S24787991432008052100000) .
  4. Remove the fender. Refer to «REMOVAL»(ref-285328-S25102273932008052100000) .
  5. Remove the A/C condenser, if required. Refer to «REMOVAL»(ref-285317-S00192792122008052100000) .
  6. Remove the A/C lines, if required. Refer to the HEATING & AIR CONDITIONING - SERVICE INFORMATION article for recommended procedures.
  7. Remove the radiator assembly. Refer to «REMOVAL»(ref-285336-S18093903502008052100000) .
  8. Remove the air cleaner and support bracket, if required. Refer to «REMOVAL»(ref-285333-S19645591452008052100000) .
  9. Remove the integrated power module. Refer to «REMOVAL»(ref-285353-S13131918732008052100000) .
  10. Remove the bolts and position aside the wire harness and grounds, if required.
  11. Remove the upper radiator crossmember. Refer to «REMOVAL»(ref-285328-S00963505702008052100000) .
  12. Remove the headlamp. Refer to «REMOVAL»(ref-285329-S08371234882008052100000) .
  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 tubes (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 «SPECIFICATIONS»(ref-285325-S25486501212008052100000) .
  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 cab 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. Refer to «INSTALLATION»(ref-285329-S32808948692008052100000) .
  30. Install the upper radiator crossmember. Refer to «INSTALLATION»(ref-285328-S29101503382008052100000) .
  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 «INSTALLATION»(ref-285353-S31859373092008052100000) .
  33. Install the air cleaner bracket and air cleaner, if previously removed. Refer to «INSTALLATION»(ref-285333-S33243400362008052100000) .
  34. Install the radiator assembly. Refer to «INSTALLATION»(ref-285336-S14383841442008052100000) .
  35. Install the A/C lines, if previously removed. Refer to the HEATING & AIR CONDITIONING - SERVICE INFORMATION article for the recommended procedures.
  36. Install the A/C condenser, if previously removed. Refer to «INSTALLATION»(ref-285317-S00350111002008052100000) .
  37. Install the fender. Refer to «INSTALLATION»(ref-285328-S39187338502008052100000) .
  38. Install the front fender liner. Refer to «DESCRIPTION»(ref-285328-S24787991432008052100000) .
  39. Reconnect the battery ground.

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.

Scheme 38

Scheme 38: VEHICLE PREPARATION
Scheme 38: VEHICLE PREPARATION

Scheme 39

Scheme 39: CROSSMEMBER-UNDERBODY
Scheme 39: CROSSMEMBER-UNDERBODY
  1. Raise and support the vehicle.
  2. Remove the bolts (1) and nuts (3) and remove the crossmember (2).

CROSSMEMBER-UNDERBODY

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

Scheme 40

Scheme 40
Scheme 40
  1. Remove the front body mount bolt (1).
  2. Remove the nuts (3) and remove the tow hook.

HOOK-TOW

  1. Install the support brackets and install the bumper support nuts (3).
  2. Tighten the nuts (3) to 109 N.m (80 ft. lbs.).
  3. Install the front body mount bolt (1) and tighten to 81 N.m (60 ft. lbs.).
  4. Install the support bracket (2) nuts (3) and tighten to 109 N.m (80 ft. lbs.).

Scheme 41

Scheme 41: SKID PLATE-FUEL TANK
Scheme 41: SKID PLATE-FUEL TANK
  1. Raise and support the vehicle.
  2. Support the skid plate with a suitable lifting device.
  3. Remove inboard bolts (4).
  4. Remove bolts (3) that attach skid plate to frame side rail and remove the skid plate.

SKID PLATE-FUEL TANK

  1. Position and support skid plate under fuel tank.
  2. Install inboard bolts and tighten to 41 N.m (30 ft. lbs.).
  3. Install bolts attaching skid plate to frame side rail and tighten to 37 N.m (27 ft. lbs.).

RECEIVER KIT-TRAILER TOW

  1. Remove the rear bumper. See «REMOVAL»(ref-285325-S40255950412008052100000) .
  2. Remove the rear cab to frame bolts (3) and rebound cushions (2) to remove the front hitch bolt.
  3. Support trailer hitch on a suitable lifting device.
  4. Disconnect the trailer electrical wiring electrical connector.
  5. Remove the bolts (3 and 5) and nuts (2) attaching trailer hitch (4) to frame rails (1).
  6. Separate trailer hitch (4) from vehicle.
  1. Position trailer hitch on vehicle.
  2. Install the bolts and nuts (2, 3 and 5) attaching trailer hitch to frame rail and tighten to 183 N.m (135 ft. lbs.).
  3. Connect the trailer wiring electrical connector.
  4. Install the rear body rebound cushions (2) and cab mounting bolts (3) and tighten to 81 N.m (60 ft. lbs.).
  5. Install the rear bumper. See «INSTALLATION»(ref-285325-S31188552712008052100000) .

Scheme 42

Scheme 42: SKID PLATE-TRANSFER CASE
Scheme 42: SKID PLATE-TRANSFER CASE
  1. Remove the bolts (1) and remove the skid plate (2).

SKID PLATE-TRANSFER CASE

  1. Position the skid plate (2) on the vehicle.
  2. Install the bolts (1) and tighten to 23 N.m (17 ft. lbs.).

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