Frame & Bumpers: Removal & Installation Dodge Durango II рестайлинг

FRONT FRAME RAIL TIP REPLACEMENT

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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 front bumper. See «REMOVAL»(ref-285325-S18272920092008052100000) .
5. Remove the washer bottle, if required.
6. Remove the front cab mount bolt (1) to the Front End Sheet Metal (FESM) bracket and the lower bumper support nuts (3) attaching the tow hook (2), 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.
7. Using a reciprocating saw (2) or equivalent, carefully cut and remove the damaged frame rail tip behind the stop bracket (1).
8. Remove the brake lines as necessary, to gain access to the upper fillet welds. Refer to «REMOVAL»(ref-285321-S28595167072008052100000) .
9. For the right side rail tip, remove the oil filter to gain access to the inner fillet weld.
10. Remove the four puddle welds attaching the remaining frame tip section (2) to the frame (1) at the locations indicated. (Right side shown, left side similar.)
11. Using a plasma cutter, remove the welds (4) by cutting along the outside edge of the weld (1) approximately 3 mm (1/8 in.) (2).
12. With the puddle welds (1) removed, remove the remaining piece of the frame tip (2) from within the frame rail and discard.
13. Smooth and square the cut edges of the original frame.
14. Remove any burrs at the holes (1) and frame edges.
15. Dry fit the new rail (2) to verify alignment, fit and make any adjustments as necessary.
16. Remove all internal and external OEM e-coat within 51 mm (2.0 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.
17. Loosely install the lower FESM insulator and cab mounting bolt.
18. Position the stop bracket (2) against the frame rail (1). NOTE: If replacing the drivers's side tip, the stop bracket mounting tab will not be utilized. The stop bracket may be rotated about the narrow end of the trip and repositioned so interference of tab with other parts is avoided. The mounting tab my also be cut off. NOTE: If replacing the passenger's side tip, the stop bracket mounting tab may be utilized if the vehicle is equipped with optional rear AC system.
19. 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 «SPECIFICATIONS»(ref-285325-S25486501212008052100000) . CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
20. 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.
21. Confirm alignment of the replacement frame rail tip.
22. 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 section. The preferred method is GMAW (MIG). See «SPECIFICATIONS»(ref-285325-S25486501212008052100000) . 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.
23. 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.
24. 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.
25. Install the tow hook assembly (2), if equipped, and install the two lower bumper support nuts (3).
26. Tighten the nuts (3) to 109 N.m (80 ft. lbs.).
27. Install the front end sheet metal mount bolt (1) and tighten to 81 N.m (60 ft. lbs.).
28. Install the front bumper. See «INSTALLATION»(ref-285325-S37048263902008052100000) .
29. Install the front fender liner. Refer to «DESCRIPTION»(ref-285328-S24787991432008052100000) .

REAR FRAME RAIL TIP REPLACEMENT

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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 (ground) cable.
3. Disconnect all wire harness connectors from the Occupant Restraint Controller (ORC). Refer to «REMOVAL»(ref-285335-S40005458892008052100000) .
4. Remove the trailer hitch. See «REMOVAL»(ref-285325-S39121615002008052100000) .
5. As necessary, loosen the body isolators and remove the rear two in order to lift the body slightly when performing the final welding of the spare tire support crossmember. Refer to «REMOVAL»(ref-285328-S39142240102008052100000) . 1 - TUBULAR CROSSMEMBER 2 - FASCIA SUPPORT BRACKET HOLE 3 - REPLACEMENT FRAME TIP 4 - CUTLINE - 81 mm (3.2 in.) 5 - 257 mm (10.12 in.)
6. Make a vertical mark (4) on the inside and outside face of the frame rail 257 mm (10.12 in.) (5) from the rearward edge of the tubular crossmember (1) or 81 mm (3.2 in.) from the rearward edge of the forward fascia support bracket hole (2).
7. Using a straightedge, connect the two lines on the top and bottom of the rail.
8. Using the service tip as a guide, check your cut lines to ensure the service tip will fit when the cut is made. CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. This is due to the inaccurate nature of the cut-line and the fact that the high temperatures achieved during flame or plasma cutting will change the metal characteristics and may weaken the frame and/or repair location.
9. Using a reciprocating saw or equivalent (1), carefully cut the spare tire support crossmember (2) from the frame tip.
10. Using a reciprocating saw or equivalent, carefully cut (3) and remove the damaged frame rail tip (2). 1 - FRAME 2 - REPLACEMENT FRAME TIP 3 - FILLET WELD LOCATION 38 mm (1.5 in.) 4 - FILLET WELD LOCATION 19 mm (0.75 in.) 5 - RING FILLET WELD HOLES NOTE: Any burned surface coatings will need to be removed from the sleeve prior to installation and application of corrosion preventative coatings.
11. Smooth and square the cut edges of the original frame (1) and dress the cut edge in preparation for the new rail tip.
12. Drill four 13 mm (0.5 in.) diameter holes (5) in the new tip (2) and four more in the existing frame (1) to accommodate ring-fillet welds. Center these holes 19 mm (0.75 in.) from the cut face of the rail (4) and (3) 38 mm (1.5 in.) from the top and bottom of the rail (3). 1 - FRAME REPLACEMENT TIP 2 - FRAME RAIL 3 - FRAME DRESS ANGLE 25°-30° 4 - ROOT PASS 5 - COVER PASS 6 - SERVICE SLEEVE 7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 8 - SERVICE SLEEVE
13. Bevel the edges of the new tip, existing frame, and ring-fillet holes 25° - 30° (3). Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy.
14. Remove any burrs at the holes and beveled edges.
15. Dry fit the new rail to ensure alignment and fit and make any adjustments as necessary.
16. Remove all internal and external OEM e-coat within 51 mm (2.0 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.
17. Find the centerline of the sleeves and scribe a centerline mark (1). Mark two additional lines (3) 2 mm (0.08 in.) on either side of the centerline mark to help ensure the required 4 mm - 6 mm (0.16 in. - 0.24 in.) weld root gap.
18. Install the sleeve halves into the frame. Install one half of the service sleeve (3) into the frame (4). Slide the service sleeve (3) into the frame (4) and align to the 2 mm (0.08 in.) off center line (2) made previously and tack the ring fillet welds (1) to hold them in place.
19. Install the remaining half of the service sleeve (2) into the frame (4). Slide the service sleeve (2) into the frame (4) and align to the 2 mm (0.08 in.) off center line (3) made previously and tack the ring fillet welds (1) to hold them in place.
20. Install the replacement frame tip.
21. Using the appropriate measuring equipment, verify the frame tip's location in all three (X, Y, and Z) planes of space, and adjust if required. 1 - FRAME REPLACEMENT TIP 2 - FRAME RAIL 3 - FRAME DRESS ANGLE 25°-30° 4 - ROOT PASS 5 - COVER PASS 6 - SERVICE SLEEVE 7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 8 - SERVICE SLEEVE CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
22. When correctly fitted and a weld root gap of 4 mm minimum to 6 mm maximum (0.16 in - 0.24 in) is established, tack the ring fillet welds to hold the tip in position. 1 - WELD START LOCATION 2 - WELD END LOCATION 3 - RING-FILLET WELD
23. Complete the ring fillet welds. NOTE: Ring-fillet welds may be filled in with weld material if an improved cosmetic appearance is desired.
24. Confirm alignment of the replacement frame rail tip (4). 1 - FRAME REPLACEMENT TIP 2 - FRAME RAIL 3 - FRAME DRESS ANGLE 25°-30° 4 - ROOT PASS 5 - COVER PASS 6 - SERVICE SLEEVE 7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 8 - SERVICE SLEEVE
25. 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 section. The preferred method is GMAW (MIG). See «SPECIFICATIONS»(ref-285325-S25486501212008052100000) . Apply root pass welds (4) to the root joint 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 (5). Apply the cover pass welds (5) in the same manner as described above.
26. 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.
27. Weld the spare tire support bracket to the replacement frame tip in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the Weld Process Specifications at the end of this section. The preferred method is GMAW (MIG). See «SPECIFICATIONS»(ref-285325-S25486501212008052100000) .
28. Dress the welded areas 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 areas.
29. Install the rear body isolators, lower the body and tighten all body isolators. Refer to «INSTALLATION»(ref-285328-S14126775542008052100000) .
30. Install the trailer hitch. See «INSTALLATION»(ref-285325-S16711191852008052100000) .
31. Connect the Occupant Restraint Controller (ORC). Refer to «INSTALLATION»(ref-285335-S10371543152008052100000) .
32. Connect battery negative cable.