Chrysler 300C, Charger 2005, 300C 2005 User Manual

CHRYSLER 300, 300C, 300 TOURING SEDANS AND

DODGE MAGNUM BODY REPAIR MANUAL

SAFETY NOTICE

CAUTION

All SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies

in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product.

Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service produces recommended and described in this publication were developed for professional service personnel, and are effective methods for performing vehicle repair. Following these procedures will help ensure efficient economical vehicle performance and service reliability. Some service procedures require the use of special tools designed for specific procedures. These special tools should be used as recommended throughout this publication.

Special attention should be exercised when working with spring-or tension-loaded fasteners and devices such as EClips, Circlips, Snap rings, etc., since careless removal may cause personal injury. Always wear safety goggles when working on vehicles or vehicle components.

It is important to note that this publication contains various Cautions and Warnings. These should be read carefully in order to minimize risk of personal injury or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended. DaimlerChrysler Corporation cannot possibly know, evaluate, and advise the service trade of all conceivable ways in which service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler has not undertaken any such broad service review. Accordingly, anyone uses a service procedure or tool that is not recommended in this publication must be certain that neither personal safety, nor vehicle safety, will be jeopardized by the service methods they select.

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BONDING MANUAL

Copies of the Pacifica (81-316-0530CD), Durango (81-31-0430CD) & PT Convertible (81-316-0531CD) Body Repair Manuals are available by calling 1-800-890-4038

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Introduction

CHRYSLER 300, 300C,

300 Touring

and

DODGE MAGNUM

This manual has been prepared for use by all body technicians involved in the repair of the 300, 300C, 300 Touring & Dodge Magnum

This manual shows:

- Typical unibody panels contained in these vehicles - The types of welds for the panel

- The weld locations for these panels - Proper sealer types and correct locations

Body Construction Characteristics......................

History of Collision Repair...................................

Body Code Plate Information..............................

Vehicle Identification Number Information...........

Corrosion Protection............................................

Welded Panel Replacement................................

Sealer Locations..................................................

Sound Deadner Locations...................................

Structural Adhesive Locations.............................

Frame/Body Dimensions.....................................

Additional Support/Information............................

DaimlerChrysler Motors Corporation reserves the right to make improvements in design or to change specifications to these vehicles without incurring any obligation upon itself.

BODY CONSTRUCTION CHARACTERISTICS

Definitions of Steels used in the 300,300C, & Magnum: MS 66 - Represents an uncoated Hot Rolled Steel Sheet used mainly for interior braces and reinforcements.

MS 67 - Represents an uncoated Cold Rolled Sheet structural steel used in areas where structural integrity is critical. EG., the type of steel used for the "A" pillar.

MS 264 - Represents an uncoated high strength low alloy (HSLA) steel used in applications where structural integrity is

critical.

MS 6000-44A - Low carbon, hot dipped galvanneal (or EGA) with 45 g/m² minimun coating weight on both sides.

- Most common Sheet Steel product used by Chrysler

MS 6000-44VA - 50 ksi min. yield strength, HSLA, killed steel, with 44 g/m² minimun coating weight on both sides. -

- Most common high strength coated steel product used by Chrysler

BODY CONSTRUCTION CHARACTERISTICS

The following measures have been implemented in order to provide maximum corrosion prevention and protection.

1. The use of galvannealed coatings throughout the body structure.

2. Ecoat is used on the complete body in all instances.

3. Body sealing.

4. Stone-chipping resistant primer application.

5. Underbody corrosion prevention.

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

CAR LINE

CHART A C D D MIN

PART L 4 4 4 PART GAGE

L 8 8 9 DESCRIPTION METRIC MATERIAL

#

4 C TROUGH - DECK OPENING SIDE RT 1.24 MS-6000 44A

C TROUGH - DECK OPENING SIDE LT

4 8 TROUGH - DECK OPENING SIDE RT 1.24 MS-6000 44A

8 TROUGH - DECK OPENING SIDE LT

4 D TROUGH - QTR PANEL DRAIN UPR RT 1.52 MS-6000 44VA-040SK

D TROUGH - QTR PANEL DRAIN UPR LT

7 A BRACKET - FRT SUSP UPR CONTROL ARM R 1.98 MS-6000 44VA-050XK

A BRACKET - FRT SUSP UPR CONTROL ARM L

9 A PANEL - RR WHEELHOUSE INR RT 1.22 MS-6000 44A

A PANEL - RR WHEELHOUSE INR LT

10 A REINFORCEMENT - SILL FRT RT 0.99 MS-6000 44VA-050-XF

A REINFORCEMENT - SILL FRT LT

12 A PANEL - RR WHEELHOUSE OTR RT 0.61 MS-6000 44A

A PANEL - RR WHEELHOUSE OTR LT

13 C PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK

C PANEL - BODY SIDE INR LT

COMPONENT CHART PART SPECIFICATION LIST

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

13 8 PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK

8 PANEL - BODY SIDE INR LT

13 D PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK

D PANEL - BODY SIDE INR LT

15 C PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE

C PANEL - BODY SIDE OTR LT

15 8 PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE

8 PANEL - BODY SIDE OTR LT

15 D PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE

D PANEL - BODY SIDE OTR LT

17 A PANEL - RR SHOCK MOUNTING RT 2.00 MS-6000 44VA-050-XK

A PANEL - RR SHOCK MOUNTING LT

18 A TAPPING PLATE - DOOR HINGE FRT RT 2.40 MS-66

A TAPPING PLATE - DOOR HINGE FRT LT

18 A TAPPING PLATE - DOOR HINGE FRT LT 2.40 MS-66

23 A BRACKET - ENGINE CRADLE MOUNTING UPR 1.80 MS-6000 44VA-050-XK

A BRACKET - ENGINE CRADLE MOUNTING UPR

25 A REINFORCEMENT - TOEBOARD CROSSMEMBER 1.98 MS-6000 44VA-080-XK

A REINFORCEMENT - TOEBOARD CROSSMEMBER

26 A PANEL - UPR LOAD PATH OTR RT 0.89 MS-6000 44VA-050-XK

A PANEL - UPR LOAD PATH OTR LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

27 A BRACKET - ENGINE CRADLE MOUNTING UPR 1.47 MS-6000 44VA-050-XK

28 A SPACER - BRAKE BOOSTER 3.50 MS - 588 -B - 3

31 A PANEL - SHOCK TOWER MOUNTING FRT RT 2.08 MS-6000 44A

A PANEL - SHOCK TOWER MOUNTING FRT LT

32 A PANEL - FRT WHEELHOUSE RR RT 0.76 MS-6000 44A

A PANEL - FRT WHEELHOUSE RR LT

33 D PANEL - HOOD INR 0.90 MS-8580 A96022-T43

C PANEL - HOOD INR 8 PANEL - HOOD INR

34 D PANEL - HOOD OTR 0.90 MS-8580 A96022-T4E29

C PANEL - HOOD OTR 8 PANEL - HOOD OTR

35 A TAPPING PLATE - HOOD INR PANEL HINGE 2.00 MS-8580 A96022-T4

A TAPPING PLATE - HOOD INR PANEL HINGE

36 C CROSSMEMBER - HEADLAMP MOUNTING MS-DB-41/MS-6000 44VA

D CROSSMEMBER - HEADLAMP MOUNTING 8 CROSSMEMBER - HEADLAMP MOUNTING

38 A PAN - TORQUE BOX RT 2.50 MSDB543,CPN2194,TYPEA

39 A PANEL - FRT WHEELHOUSE FRT RT 1.42 MS-6000 44VA-050

A PANEL - FRT WHEELHOUSE FRT LT

41 A TAP PLATE - FLOATING 1.98 MS-66

44 A PANEL - LWR RADIATOR CROSSMEMBER 0.79 MS-67

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

49 C REINF - HOOD INR PANEL SLAM 1.25 MS-8580 A96022-T4

D REINFORCEMENT - HOOD INR PANEL SLAM 8 REINFORCEMENT - HOOD INR PANEL SLAM

51 A PANEL - RAIL FRT COVER RT 1.54 MS-6000 44VA-590DT

A PANEL - RAIL FRT COVER LT

53 A PANEL - FRT SIDE RAIL INR RT 1.54 MS-6000 44VA-590DT

A PANEL - FRT SIDE RAIL INR LT

54 A PANEL - COWL LWR 0.89 MS-6000 44A

55 A BRACKET - ICU 1.47 MS-6000 44A

56 A PANEL - COWL UPR 0.71 MS-6000 44A

58 A PANEL - DASH 0.71 MS-6000 44A

62 A PANEL - EXTENSION FRT RAIL OTR RT 1.98 MS-6000 44VA-050-XK

A PANEL - EXTENSION FRT RAIL OTR LT

63 A PANEL - EXTENSION FRT RAIL INR RT 1.88 MS-6000 44VA-050-XK

A PANEL - EXTENSION FRT RAIL INR LT

64 A SHIELD - SPLASH RR WHEELHOUSE RT 2.00 MSDB-543,TYPE A

A SHIELD - SPLASH RR WHEELHOUSE LT

65 A REINF - RAIL TO TUNNEL RT 1.04 MS-264 035-SK

A REINF - RAIL TO TUNNEL LT

66 A COVER PLATE - RAIL RR RT 1.24 MS-6000 44VA-050-XK

A COVER PLATE - RAIL RR LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

67 A ROD ASSY - HOOD SUPPORT 8.00 MS-284

68 A REINF - TUNNEL 1.19 MS-264 050-XF

69 A EXTENSION - RAIL FRT RT 1.40 MS-264 050-XK

A EXTENSION - RAIL FRT LT

70 A PANEL - FRT FLOOR PAN TUNNEL CTR 0.89 MS-6000 44VA-050-XF

71 A TAPPING PLATE - HINGE BODY 1.27 MS-6000

72 A REINF - I/P BRACKET RT 2.00 MS-66

A REINF - I/P BRACKET LT

73 A PANEL - LOAD PATH BEAM UPR INR RT 0.89 MS-6000 44VA-050-XF

A PANEL - LOAD PATH BEAM UPR INR LT

76 A RETAINER - RR DOOR STRIKER RT 1.52 MS-66

A RETAINER - RR DOOR STRIKER LT

77 A CROSSMEMBER - ISOFIX 1.50 MS-264 050-XK

78 A GLASS ASSY - WINDSHIELD 5.10 MS-10472-B

79 C PANEL - ROOF OTR 0.74 MS-67

8 PANEL - ROOF OTR D PANEL - ROOF OTR D PANEL - ROOF OTR

80 A REINF - HOOD INR PANEL STRIKER 2.00 MS-8580 A96022-T4

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

81 C GLASS ASSY - RR WDO ELEC HEATED E-MA 3.90 MS-10472-C

8 GLASS ASSY - RR WINDOW ELECTRIC HEAT " D GLASS ASSY - RR WINDOW ELECTRIC HEAT " MS-7588

82 C HEADER - RR WINDOW OPENING 0.74 MS-67

82 8 HEADER - RR WINDOW OPENING 0.74 MS-67

82 D HEADER - REAR UPR 1.30 MS-6000 44A

84 D HEADER - REAR LWR 0.89 MS-67

85 A HEADER - WINDSHIELD OPENING 0.74 MS-67

86 A CROSSMEMBER - FRT SEAT FRT RT 1.24 MS-264 050-XF

A CROSSMEMBER - FRT SEAT FRT LT

87 A CROSSMEMBER - FRT SEAT RR RT 1.24 MS-264 050-XF

A CROSSMEMBER - FRT SEAT RR LT

89 A EXTENSION - TUNNEL 1.47 MS-6000 44A-050-XF

90 C D BUMPER - HOOD ADJUSTER 0.00 MS-Z-77

91 A CROSSMEMBER - RR KICK-UP 0.99 MS-6000 44A

92 A BRACE - FRONT SHOCK TOWER 1.00 MS-67

94 A TAP PLATE - REAR DOOR UPR RT 2.00 MS-66

96 A PAN - CTR FLOOR PAN 0.66 MS-6000 44A

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

98 A PAN - REAR FLOOR 0.71 MS-6000 44A

101 C REINF - RR SHELF PANEL RR 0.70 MS-6000 44A

101 8 REINF - RR SHELF PANEL RR 0.70 MS-6000 44A

102 C PANEL - DECK LID OTR 0.90 MS-8580 A96022-T43

102 8 PANEL - DECK LID OTR 0.76 MS-6000 44WAE-025-SK

102 D PANEL - LIFTGATE OTR LWR 0.81 MS-6000 44AE

103 C PANEL - DECK LID INR 1.00 MS-8580 A96022-T43

103 8 PANEL - DECK LID INR 0.71 MS-6000 44A

103 D PANEL - LIFTGATE INR 1.22 MS-6000 44AE

105 C PANEL - DECK OPENING LWR INR 0.72 MS-6000 44A

105 8 PANEL - DECK OPENING LWR INR 0.71 MS-6000 44A

105 D REINF - DECK OPENING LWR INR 0.81 MS-67

106 C PANEL - DECK OPENING LWR OTR 0.72 MS-6000 44A

106 8 PANEL - DECK OPENING LWR OTR 0.71 MS-6000 44A

106 D PANEL - DECK OPENING LWR OTR 1.12 MS-6000 44A

107 A TAP PLATE - FRONT DOOR UPR RT 2.00 MS-67

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

110 A TAPPING PLATE - DOOR HINGE RR LWR RT 2.40 MS-66

A TAPPING PLATE - DOOR HINGE RR LW R LT

112 A CROSSMEMBER - RR SUSPENSION RR 1.75 MS-6000 44VA-050-XK

113 A BRACKET - ENGINE CRADLE MOUNTING LWR 1.80 MS-6000 44VA-050-XK

A BRACKET - ENGINE CRADLE MOUNTING LWR

114 A RAIL - RR INR RT 1.14 MS-6000 44VA-050-XK

A RAIL - RR INR LT

115 A BRACKET - HEADLAMP MOUNTING RT 1.24 MS-6000 44A

A BRACKET - HEADLAMP MOUNTING LT

117 D PANEL - FRONT FENDER RT 0.71 MS-6000 44WAE-025

D PANEL - FRONT FENDER LT C PANEL - FRONT FENDER RT C PANEL - FRONT FENDER LT

117 8 PANEL - FRONT FENDER RT 0.71 MS-6000 44WAE-025

8 PANEL - FRONT FENDER LT

118 C D PANEL - FRT DOOR INR RT 0.75 MS-6000 44A

C D PANEL - FRT DOOR INR LT

118 8 PANEL - FRT DOOR INR RT 0.75 MS-6000 44A

8 PANEL - FRT DOOR INR LT

119 C D REINF - FRT DOOR BELT INR RT 0.90 MS-264 050-XK

C D REINF - FRT DOOR BELT INR LT

119 8 REINF - FRT DOOR BELT INR RT 1.20 MS-264 050-XK

8 REINF - FRT DOOR BELT INR LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

121 A SHIELD - HEAT FRT FLOOR TUNNEL LT 0.50 MS-8580

123 A SHIELD - HEAT FRT FLOOR FRT RT 3.00 MS-8580

A SHIELD - HEAT FRT FLOOR FRT LT

124 A BAR - IMPACT FRT DOOR RT 2.40 MS-8010 D

A BAR - IMPACT FRT DOOR LT

125 D ROD - LIFTGATE GAS PROP 0.00 N/A

125 C PROP ASSY - DECK LID 0.00 N/A

125 8 PROP ASSY - DECK LID 0.00 N/A

126 A EXTENSION - CROSSMEMBER END SUPPORT 2.24 MS-6000 44VA-050-XK

A EXTENSION - CROSSMEMBER END SUPPORT

128 C D REINF - FRT DOOR BELT OTR RT 0.75 MS-6000 44A

C D REINF - FRT DOOR BELT OTR LT

128 8 REINF - FRT DOOR BELT OTR RT 0.75 MS-6000 44A

8 REINF - FRT DOOR BELT OTR LT

129 C D PANEL - RR DOOR INR RT 0.74 MS-6000 44A

C D PANEL - RR DOOR INR LT

129 8 PANEL - RR DOOR INR RT 0.74 MS-6000 44A

8 PANEL - RR DOOR INR LT

132 C D PANEL - REAR DOOR OUTER RT 0.76 MS-6000 44VAE-030-HK

C D PANEL - REAR DOOR OUTER LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

132 8 PANEL - REAR DOOR OUTER RT 0.76 MS-6000 44VAE-030-HK

8 PANEL - REAR DOOR OUTER LT

133 A C D REINFORCEMENT - NONE 2.00 MS-6000 44A

134 A BAR - IMPACT RR DOOR RT 2.20 MS-8010

A BAR - IMPACT RR DOOR LT

137 C PANEL - REAR SHELF 0.89 MS-67

137 8 PANEL - REAR SHELF 0.89 MS-67

139 C D PANEL - FRT DOOR OTR RT 0.76 MS-6000

C D PANEL - FRT DOOR OTR LT

139 8 PANEL - FRT DOOR OTR RT 0.76 MS-6000

8 PANEL - FRT DOOR OTR LT

140 A SPACER - CRADLE RR 3.00 MS-1560

141 C D REINFORCEMENT - REAR DOOR BELT OTR R 0.76 MS-6000

C D REINFORCEMENT - REAR DOOR BELT OTR L

141 8 REINFORCEMENT - REAR DOOR BELT OTR R 0.76 MS-6000

8 REINFORCEMENT - REAR DOOR BELT OTR L

142 A EXTENSION - IMPACT BEAM FRT DOOR FRT 1.50 MS-264 050 XK

A EXTENSION - IMPACT BEAM FRT DOOR FRT

143 A EXTENSION - IMPACT BEAM FRT DOOR RR 1.50 MS-264 050 XK

A EXTENSION - IMPACT BEAM FRT DOOR RR

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

144 A EXTENSION - RR DOOR IMPACT BAR FRT R 1.50 MS-264 050 XK

A EXTENSION - REAR DOOR IMPACT BAR FRT

145 A EXTENSION - RR DOOR IMPACT BAR RR RT 1.50 MS-264

A EXTENSION - REAR DOOR IMPACT BAR RR

146 A SPACER - ENGINE CRADLE MOUNTING FRT 3.00 MS-345 TYPE 5

148 A REINFORCEMENT - REAR RAIL OTR RT 1.98 MS-6000 44VA-050-XK

A REINFORCEMENT - REAR RAIL OTR LT

149 C D BRACKET - BUMPER RR 2.00 MS-6000 44VA-050-XK

152 A REINF - SEAT BELT ANCHOR RR INBOARD 1.98 MS-6000 44VA-050-XK

154 C REINF - C-PILLAR RT 1.19 MS-6000 44VA-050-XK

C REINF - C-PILLAR LT D REINF - C-PILLAR RT D REINF - C-PILLAR LT

154 8 REINF - C-PILLAR RT 1.19 MS-6000 44VA-050-XK

8 REINF - C-PILLAR LT

155 C REINF - DECK LID LATCH MOUNTING 2.00 MS-8580 A96022-T4

155 8 REINF - DECK LID LATCH MOUNTING 1.80 MS-66

156 D REINF - LIFTGATE HINGE MOUNTING RT 2.03 MS-66

D REINF - LIFTGATE HINGE MOUNTING LT

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156 C REINF - DECK LID HINGE TO DECK LID M 2.00 MS-8580 A96022-T4

C REINF - DECK LID HINGE TO DECK LID M

156 8 REINF - DECK LID HINGE TO DECK LID M 2.00 MS-66

8 REINF - DECK LID HINGE TO DECK LID M

157 A BRACKET - LWR RADIATOR CROSSMEMBER S 1.98 MS-264 050-XK

A BRACKET - LWR RADIATOR CROSSMEMBER S

159 A STRIKER - HOOD 7.00 MS-5378 B

160 D EXTENSION - QTR OTR PANEL LWR RR RT 0.89 MS-6000 44A

D EXTENSION - QTR OTR PANEL LWR RR LT

160 C EXTENSION - QTR OTR PANEL LWR RR RT 0.66 MS-6000 44A

C EXTENSION - QTR OTR PANEL LWR RR LT

160 8 EXTENSION - QTR OTR PANEL LWR RR RT 0.66 MS-6000 44A

8 EXTENSION - QTR OTR PANEL LWR RR LT

161 A BRACKET - VAPOR CANISTER 1.60 MS-6000 44A

A BRACKET - VAPOR CANISTER

162 D PANEL - LIFTGATE OTR UPR 0.81 MS-6000 44AE

164 C D DOOR - FUEL FILLER 0.79 MS-6000 44AE

164 8 DOOR - FUEL FILLER 0.79 MS-6000 44AE

165 C D REINFORCEMENT - REAR DOOR BELT INR R 0.90 MS-264 050-XK

C D REINFORCEMENT - REAR DOOR BELT INR L

165 8 REINFORCEMENT - REAR DOOR BELT INR R 0.90 MS-264 050-XK

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

166 C D REINF - BODY SIDE RT 1.42 MS-6000 44VA-050-XK

C D REINF - BODY SIDE LT

166 8 REINF - BODY SIDE RT 1.42 MS-6000 44VA-050-XK

8 REINF - BODY SIDE LT

167 C BRACKET - LOCK CYLINDER ATTACH 0.90 MS-67

167 8 BRACKET - LOCK CYLINDER ATTACH 1.20 MS-66

168 C 8 PANEL - RR SHELF SUPPORT RT 1.24 MS-67

C 8 PANEL - RR SHELF SUPPORT LT

172 A SPACER - TOWER BRACE 1.98 MS-66

173 A BRACKET - BATTERY RETAINER MS-DB21

176 C D REINF - B-PILLAR 1.52 MS-264 050-XK

C D REINF - B-PILLAR

176 8 REINF - B-PILLAR 1.52 MS-264 050-XK

8 REINF - B-PILLAR

178 A REINF - BRAKE BOOSTER 1.88 MS-66

179 A TAPPING PLATE - NONE 2.54 MS-66

180 A RAIL - RR OTR RT 1.42 MS-6000 44VA-050-XK

A RAIL - RR OTR LT

181 A COVER PLATE - RR RAIL EXTENSION RT 0.79 MS-6000 44A

A COVER PLATE - RR RAIL EXTENSION LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

183 A HINGE ASSY - FRT DOOR LWR RT 6.00 MS-264 050-X

A HINGE ASSY - FRT DOOR LWR LT

184 A HINGE ASSY - RR DOOR LWR RT 6.00 MS-264 050-X

A HINGE ASSY - RR DOOR LWR LT

186 C D HOUSING - RR QTR OTR PANEL FUEL FILL 1.00 MS-6000 44A

8

188 A BRACKET - CRADLE ATTACHING RT 1.98 MS-6000 44VA-050-XK

A BRACKET - CRADLE ATTACHING LT

189 A BRACKET - WIPER MODULE MTG 1.88 MS-6000 44A

190 A BRACKET - FENDER ATTACH 1.02 MS-2501

191 C HINGE ASSY - DECK LID COMP RT 3.00 MS-264 030-S

C HINGE ASSY - DECK LID COMP LT

191 8 HINGE ASSY - DECK LID COMP RT 3.00 MS-264 030-S

8 HINGE ASSY - DECK LID COMP LT

193 A BRACKET - HEADLAMP MOUNTING RT 1.98 MS-66

A BRACKET - HEADLAMP MOUNTING LT

198 A HINGE ASSY - HOOD RT 3.00 MS-264 050-X

A HINGE ASSY - HOOD LT

199 A HINGE ASSY - FRT DOOR UPR RT 6.00 MS-264 050-X

A HINGE ASSY - FRT DOOR UPR LT

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

200 A HINGE ASSY - RR DOOR UPR RT 6.00 MS-264 050-X

A HINGE ASSY - RR DOOR UPR LT

206 A BRKT - RETAINER ENGINE CRADLE T/PLT 1.44 MS-6000 55P

207 A REINF - SPARE TIRE HOLD DOWN 0.99 MS-67

211 A REINF - DASH PANEL 1.22 MS-6000 VA-050

212 A PANEL - TOEBOARD CROSSMEMBER 1.80 MS-6000 44VA-600DT

214 A REINF - JOUNCE 1.47 MS-6000 44VA-040-XK

215 C BRACKET - DISABLED VEHICLE TIE DOWN 1.98 MS-264 050-XK

218 C 8 TAPPING PLATE - DECK LID STRIKER 2.00 MS-66

218 D REINF - STRIKER PLATE 1.52 MS-66

219 C 8 STRIKER - D/LID LATCH 1.80 MS-67

220 A REINF - SHOCK TOW ER TO LOAD BEAM RT 1.47 MS-6000 44A

A REINF - SHOCK TOWER TO LOAD BEAM LT

222 A BRACKET - TRANS MOUNTING RT 1.83 MS-6000 44A

A BRACKET - TRANS MOUNTING LT

223 A REINF - FRT SIDE RAIL BUMPER MOUNTIN 1.98 MS-6000 44VA-050-XK

A REINF - FRT SIDE RAIL BUMPER MOUNTIN

224 A BRACKET - TOWER BRACE WIPER ATTACHME 1.47 MS-264 050-XK

226 A REINF - FRT SHOCK TOWER RT 1.40 MS-6000 44A

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CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

228 A DOUBLER - FRT SIDE RAIL RT 1.80 MS-6000 44A

A DOUBLER - FRT SIDE RAIL LT

233 A SHIELD - FENDER WHEELHOUSE SPLASH RT 2.50 MSDB-543,CPN2194,TYPEA

A SHIELD - FENDER WHEELHOUSE SPLASH LT

235 A TRAY ASSY - BATTERY MS-DB21

236 C D TAPPING PLATE - DOOR HINGE RR UPR RT 2.40 MS-66

C D TAPPING PLATE - DOOR HINGE RR UPR LT

238 C D BOW - ROOF 1.98 MS-264 050-XK

238 8 BOW - ROOF 1.98 MS-264 050-XK

239 A PAN - TORQUE BOX LT 2.50 MSDB-543,CPN2194,TYPEA

242 A CROSSMEMBER - REAR SUSPENSION FRT 1.04 MS-6000 44VA-050-XK

243 A REINF - KICKUP CROSSMEMBER 1.35 MS-6000 44VA-050-XK

244 A BRACKET - CTR BEARING MOUNTING RT 1.52 MS-6000 44A

A BRACKET - CTR BEARING MOUNTING LT

245 C PANEL - TAIL LAMP MOUNTING RT 0.76 MS-6000 44A

C PANEL - TAIL LAMP MOUNTING LT

245 8 PANEL - TAIL LAMP MOUNTING RT 0.76 MS-6000 44A

8 PANEL - TAIL LAMP MOUNTING LT

245 D PANEL - TAIL LAMP MOUNTING RT 0.89 MS-6000 44A

D PANEL - TAIL LAMP MOUNTING LT

Back To Index

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

247 D TAP PLATE - CROSS CAR BEAM UPR 2.00 MS-66

247 C D TAPPING PLATE - SEAT BELT TURNING LO 2.50 MS-66

250 C REINF - RR BELT RETRACTOR RT 1.00 MS-67

C REINF - RR BELT RETRACTOR LT

250 8 REINF - RR BELT RETRACTOR RT 1.00 MS-67

8 REINF - RR BELT RETRACTOR LT

251 D REINF - LIFTGATE HINGE BODY HALF RT 1.50 MS-66

252 A BRACE - REINFORCEMENT TUNNEL CTR 1.98 MS-6000 66V-050XK

253 D REINF - LIFTGATE PROP ROD RT 1.22 MS-67

D REINF - LIFTGATE PROP ROD LT

254 A BEAM ASSY - BUMPER FRT 1.20 MS-264 120-XF

255 A BEAM - REAR BUMPER 1.60 MS-264 120-XF

256 C D TAP PLATE - NONE 1.80 MS-66

258 D REINF - LIFTGATE LATCH 1.00 MS-67

261 C TAPPING PLATE - DECK LID HINGE 1.80 MS-66

261 8 TAPPING PLATE - DECK LID HINGE 2.00 MS-66

8

261 D TAPPING PLATE - PROP ROD RT 1.50 MS-67

Back To Index

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

265 D REINF - WIPER MOUNTING 1.00 MS-67

268 D REINF - BODY SIDE INR PANEL D-PILLAR 1.19 MS-264

D REINF - BODY SIDE INR PANEL D-PILLAR

269 C 8 CROSSMEMBER - RR SHELF 0.89 MS 67

271 A C D TAPPING PLATE - NONE 1.40 MS-66

272 A TAPPING PLATE - CROSSMEMBER 3.50 MS-66

274 A TAPPING PLATE - BODY SIDE FRT DOOR L 2.40 MS-66

A TAPPING PLATE - BODY SIDE FRT DOOR L

277 A TAPPING PLATE - SIDE AIR BAG SENSOR 2.00 MS-66

278 A PANEL - FRT FLOOR PAN RT 0.61 MS-6000 44A

A PANEL - FRT FLOOR PAN LT

280 A TAPPING PLATE - SEAT BELT RETRACTOR 3.00 MS-66

281 C BRACKET - CHILD TETHER ATTACH 2.67 MS-264 050-XK

282 C 8 REINF - CTR SEAT BELT RETRACTOR 1.65 MS-264 050-XK

283 A REINFORCEMENT - CROSSMEMBER REAR SUS 3.48 MS-264 050-XK

A REINFORCEMENT - CROSSMEMBER REAR SUS

Back To Index

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

284 A REINF - RR RAIL INR RR RT 1.52 MS-6000 44VA-080-XK

A REINF - RR RAIL INR RR LT

285 A GUSSET - ISOFIX 1.80 MS-264 050-XK

A GUSSET - ISOFIX

288 D BRACKET - SEAT BACK LATCH RR UPR RT 1.09 MS-67

D BRACKET - SEAT BACK LATCH RR UPR LT

289 D PANEL - SEAT STRIKER RT 1.09 MS-67

D PANEL - SEAT STRIKER LT

290 C D CHANNEL - FRONT DOOR GLASS RUN RT 0.90 MS-6000 44A

C D CHANNEL - FRONT DOOR GLASS RUN LT

290 8 CHANNEL - FRONT DOOR GLASS RUN RT 0.90 MS-6000 44A

8 CHANNEL - FRONT DOOR GLASS RUN LT

291 C D REINF - FUEL FILLER DOOR HINGE 1.20 MS-6000 44A

8

293 D REINF - ROOF RACK FRT 1.00 MS-67

D REINF - ROOF RACK RR

296 C D CHANNEL - RR DOOR GLASS RUN RT 0.90 MS-6000 44A

C D CHANNEL - RR DOOR GLASS RUN LT

296 8 CHANNEL - RR DOOR GLASS RUN RT 0.90 MS-6000 44A

8 CHANNEL - RR DOOR GLASS RUN LT

298 C PANEL - ROOF SUNROOF 0.74 MS-67

8 PANEL - ROOF SUNROOF D PANEL - ROOF SUNROOF

Back To Index

CHRYSLER 300, 300C, 300 TOURING, &

DODGE MAGNUM

COMPONENT CHART PART SPECIFICATION LIST

299 C D REINF - SUNROOF 1.20 MS-6000 44A

8 REINF - SUNROOF

329 A REINF - SUN VISOR MOUNTING TRIM 1.80 MS-66

A REINF - SUN VISOR MOUNTING TRIM

Back To Index

HISTORY OF COLLISION REPAIR

Time was, if you had an accident, the call went out to the insurance company - to the collision shop - or several shops get the lowest bid and in no time at all, the vehicle was repaired.

The facilities, training, and equipment were simple. Use a torch to cut, shape, and bend. Use something substantial as an anchoring point - maybe a tree and then just pull.

Use plenty of solder or body putty to make it look good. With the frame and body vehicle, the job was easy; first straighten the frame - then fix the mechanical components and the body work was cosmetic. This was all well and good until the mid - '70s.

Then, the designers, engineers, and manufacturers had to find ways to make the vehicles energy efficient - and that meant unibody cars. The unibody concept wasn't new - back in the '30s the Chrysler Air Flow had it - race cars have it and now the driving public worldwide has it.

The change came quickly. Manufacturers devoted time, money, and talent to delvelop the unibody car.

The public was ready to buy and did!

But then came the problem! The collision repair industry wasn't given the luxury of taking their time to train people in the new technology - or take time to plan for new equipment.

The collision happened and the vehicle had to be fixed. Cars that were repairable were being totalled.

Cars that were repaired were not repaired correctly. Everybody was in a quandary - auto manufacturer - insurance company - repair equipment people - body shops - and repair technicians.

The problem started in the early '70s and body shops are still catching up today. Yesterday's "ding" is today's "crash". It takes trained technicians and sophisticated equipment to do the repair today.

That's why DaimlerChrysler is taking the time and effort to get the right information into the hands of the people that handle the repair job. Back To Index

BODY CODE PLATE DESCRIPTION

The Body Code Plate is located in the engine compartment on the right headlamp mounting bracket/ radiator support. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.

BODY CODE PLATE

1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN

NOTE: Paint Code may also be found on safety certification label on inside of driver side door jamb.

Return To Index

VIN DECODING INFORMATION

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured by DaimlerChrysler Canada Inc.

C = Chrysler

2 Make

3 Vehicle Type

Restraint System

Gross Vehicle Weight

4

5 Vehicle Line

6 Series

7 Body Style

8 Engine

9 Check Digit 0 through 9 or X 10 Model Year 5 = 2005 11 Assembly Plant H = Brampton Assembly

12 Through 17 Vehicle Build Sequence

Rating H = 6001-7000 lbs.

D = Dodge 3 = Passenger Car 4 = Multipurpose Passenger Vehicle With Side Airbags 8 = Multipurpose Passenger Vehicle with Side Airbags

J = Restraint System Air bags Front Next Generation Multi-Stage Sales Code (CG1) Without Side Air Bags Sales Code (CGS)

A = 300 / 300C / SRT-8 (RWD) K = 300 (AWD) V = TBD (RWD) Z = TBD (AWD) 2 = L Low Line 3 = M Medium 4 - H High Line 5 = P Premium 6 = S Sport 7 = S Special 3 = LX - 48 8 = LX - 49 R = 2.7L V-6 cyl. DOHC 24 Valve MPI Gasoline G = 3.5L V-6 cyl. High Output 24 Valve MPI Gasoline H = 5.7L V-8 cyl. Gasoline T = 2.7L V-6 cyl. DOHC 24 Valve MPI Gasoline V = 3.5L V-6 cyl. High Output 24 Valve MPI Gasoline 2 = 5.7L V-8 cyl. HEMI Multiple Displacement Gasoline

Six Digit Number Assigned By Assembly Plant

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VEHICLE IDENTIFICATION NUMBER

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Corrosion Protection

Factory Applied Corrosion Protection

During the manufacturing of the unibody car, the manufacturer applies "corrosion protection" using specialized manufacturing processes. This system is not duplicated in the collision repair body shop. However, the body shop still has a responsibility to apply corrosion protection to the unibody vehicle. So, the collision repair shop must use alternative materials to do the corrosion protection job after the repair.

This corrosion protection is required regardless of the environment and weather conditions the vehicle will be operated in. Corrosion protection is as important in the desert as it is at the seaside. Corrosion damage can literally destroy the structural integrity of a unibody vehicle from within. Many corrosion protection systems are destroyed during collision repair operations. Metal finishing, metal working and fatigue can cause the breakdown of many of the corrosion barriers installed at the factory. The use of heat for stress relief and welding also destroys factory installed corrosion barriers. These corrosion barriers and corrosion protection systems must be replaced after collision repair to ensure that the structural integrity of the unibody will remain intact throughout its life. In the past, only vehicles with aftermarket or afterdelivery corrosion protection systems installed were serviced after collision repair to restore the corrosion protection system.

An understanding of the types of corrosion which affect the unibody vehicles will assist in understanding why the factory protection systems are important, how the factory protection systems consist of and how the systems' protection is replaced after collision and electrolytic corrosion. Some of the more common types of corrosion are crevice corrosion, pitting, galvanic corrosion, stress corrosion, cracking, fretting, and erosion corrosion. Back To Index

Corrosion Protection

Crevice corrosion

Crevice corrosion is a form of localized attack that occurs in areas on metal surfaces exposed to the elements.

Examples include spot weld lap joints, threaded or riveted connections, gasket fittings, porous welds, valve seats.

Pitting

Pitting is the corrosion of a metal surface at points or small areas which look like a small hole in the metal.

Galvanic corrosion

Galvanic corrosion is the type that occurs when dissimilar metals are in electrical contact while immersed in an

electrolyte.

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Corrosion Protection

The penetration of corrosive solutions into these small areas, with widths that are typically a few thousandths of an inch, can result in various types of failures: the metal surface may become rusty in appearance, operating components may seize when protective coatings may have been removed from the metal surface. The coating of zinc on steel, known as galvanized, is an example of sacrificial cathodic protection.

An example of galvanic corrosion on the automobile is a stainless steel trim molding on a painted mild steel. When the paint becomes damaged, a galvanic corrosion cell is formed between the passive stainless steel (cathode) and the steel (anode). The corrosion leads to what would look like a rust stain. Methods of reducing galvanic corrosion include the use of compatible materials, minimizing of cathode-to-anode areas, the insulation of dissimilar metal contacts and the use of thick, replaceable sections.

Stress corrosion, cracking, fretting, and erosion corrosion.

Corrosion cracking is the early cracking of metals produced by the combined action of tensile stress and a corrosive atmosphere.

Corrosion fatigue is cracking due to the action of stresses and corrosion. Methods of reducing corrosion fatigue include the reduction in stress and the use of coatings.

Fretting is the deterioration of a metal at contact surfaces due to the presence of a corrosive and relative motion between the surfaces. The two metal surfaces initially are covered with an oxide film that becomes abraded during vibration. The results are oxide particles that become corroded. During the collision repair process, the factory protection materials become damaged from working the metals, or from the use of heat in the repair operations. If these factory protection materials are not replaced with some similar protection material after repair, a corrosion hot spot is formed. A corrosion hot spot is a small unprotected area surrounded by a protected area throughout the rest of the vehicle. the hot spot effect causes rapid deterioration of the unprotected area. This deterioration takes place at a much faster rate, sometimes 10-12 times faster than if the entire car were unprotected. The hot spot effect is created because all the corrosive factors are channeled to the unprotected area much the same way all material flowing through a funnel is concentrated in a small area. This hot spot effect means that corrosion failures to the unibody structure could occur in a short period of time even in an atmosphere normally not subject to corrosion. The hot spot effect can cause rapid deterioration of unibody structures from corrosion damage in a desert as well as seaside.

Back To Index

Corrosion Protection

The types of materials used in rustproofing application include oil based materials, wax base materials, primers and color coats. The most important properties of rustproofing materials are adhesion, toughness, and the resistance to the environment. The best coating in the world is not effective unless it is present in the right place at the right time.

Corrosion Protection Information

When making the collision repair, refer to the manufacturer's information on where corrosion protection and sealants are applied. Be sure to follow the recommendations. The application process is usually included with the material manufacturer's information so be sure to read and understand it before proceeding with the repair.

Collision Repair Corrosion Protection Materials

The materials must provide good electrolyte barriers. The material must also be able to penetrate tiny crevices and prevent abrasive corrosion. The material must be compatible with paint systems as many areas of the car must be treated before paint is applied.

Materials containing silicones will cause paint conditions such as fish eyes if they are applied before the repaired vehicle is painted. So no silicone containing material is to be used. As many of the repair areas are more accessible before final assembly and painting, the non-silicone type materials are a must for this type of application.

When protecting an enclosed area, fog type properties for the corrosion protection material are a plus. The fog properties make the material much less susceptible to operator error or misapplication. With a fog type material, once the material is introduced inside of an enclosure, the fog spreads rapidly and evenly into all areas including tiny crevices. The fog type materials do not require direct spray application to be effective. Fog type materials are also very effective in coating over any existing rusted or corrosion damaged areas and preventing further corrosion of these areas. This is especially important on repairs of older vehicles.

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Corrosion Protection

Spray Accessibility to the Repair

Being able to achieve fog spray penetration into enclosed cavities as well as open areas requires application equipment, which includes an assortment of wands of various lengths and design.

Some areas are more effectively treated by brush application of corrosion protection material before they are assembled. A good example of this is an inner and outer engine compartment side rail area. Brush application to the inside of these areas as individual pieces is easy before assembly and can be followed by a light fog application to the weld areas and the crevices formed during assembly after the rails are assembled. Brush application keeps the foreign material from getting between welded joints during assembly yet gives good coverage to general areas with easy application. The material selected in addition to paint compatibility features and fog application features is also an excellent brush application material. Repaired areas, boxed in or closed in are more easily treated during assembly using fog and brush on techniques. Care must be taken to keep the corrosion materials away from the welding areas as welding contamination might take place. Brush-on applications are used before welding and fog in applications are used after welding assemblies together.

Back To Index

Corrosion Protection

Desired Characteristics of Corrosion Protection Material

1. Corrosion prevention material- The material must displace water to prevent corrosion. This can be tested by

spraying water on an open panel on the floor, then spraying the corrosion preventative material over the watered panel and observing if the material displaces the water.

2. Creepage of material- To insure thorough and complete protection coverage, the material should have a "creep" capability, approximately 1/4 inch per minute while drying. This assures protective penetration of pinch welds, cracks, etc.

3. Safe material- Material should be non-combustible when dried and when wet unable to support a fire after ignition.

4. Clean-up- The material should be of a viscosity which inhibits runs or drips. Overspray on a vehicle's painted surface

should wipe off easily without solvent when wet, with solvent when dry. The material should also dry clean off clothing.

5. Guarantee/Warranty- The corrosion protection has to be done to maintain factory corrosion warranty. Manufacturer's recommendations must be followed.

Glossary:

Abrasion Corrosion - Rubbing or hitting of one material by another Corrosion Protection - Material applied to deter corrosion (oxidation) Crevice Corrosion - Oxidation when two metals are joined Electrolytic Corrosion - Electrical action taking place between two materials in the presence of an electrolyte (liquid) Fogging - Applying material in a mist form Fretting - Deterioration of metal at contact surfaces due to motion and corrosive elements Galvanic Corrosion - Electrical action (electrolysis) between two dissimilar metals in the presence of electrolyte (liquid) Hot Spot - An unprotected area subject to corrosion Pitting Corrosion - Corrosion on a surface the results in a small "specks" or "pinholes" Stress of Fatigue, Cracking Corrosion - Cracking due to stress and atmospheric elements

Back To Index

247

250

329

013

274

133

018

015

190

026

117

193

073

007

039

092

172

220

055

Rt. Only

254

166

010

MODULE 49

115

223

032

031

226

224

172

176

041

113

MODULE 58

MODULE 55

277

256

236

271

053

023

051

MODULE 23

161

066

034

MODULE 7

233

161

Rt. Only

017

181

064

054

211

189

058

038

067

MODULE 66

159

245

MODULE 70

MODULE 35

025

009

261

004

MODULE 8

035

033

090 (4)

049

080

MODULE 54

160

076

271

012

154

110

206

146

157

212

062

027

063

MODULE 9

036

044

157

CHRYSLER 300/DODGE MAGNUM

COMPONENT CHART

238

078

056

029

178

239

198

228

087

086

069

065

215

27

2

(8)

086

069

222

085

022

252

087

072

222

191

235

098

MODULE 26

200

184

125

255

102

103

155

173

296

165

094

191

MODULE 33

207

MODULE 37

Left Side

141

132

149

218

015

LX BODY COMPONENT CHART MATERIAL KEY

High Strength

Mild Steel

Bake

MODULE 81

129

PURPLE

ORANG

GREEN

186

144

RED

GRAY

149

219

MODULE 61

145

134

Aluminum

Glass

Plastic

Dual Phase

MODULE 25

291

MODULE 31

LASTLAST

LAST

167

106

105

164

BLUE

CLEAR

YELLOW

TURQUOISE

298

068

278

070

MODULE 16

123

081

079

281

282

168

269

168

096

243

152

091

278

MODULE 27

121

133

152

MODULE 30

MODULE 41

206

126

283

114

284

199

183

281

077

MODULE 80

142

137

179

242

126

180

179

107

143

124

082

244

072

089

MODULE 51

299

156

101

MODULE 45

285

214

112

MODULE 79

280

140

188

148

290

119

118

128

139

Note: To read numbers enlarge art to 200%. Back To Index

Welded Panel Replacement

CHRYSLER 300, 300C,

300 Touring

and

DODGE MAGNUM

The basic parts of the body structure are the welded panels. This section contains a brief description of the placement of some of the panels and their weld locations.

Note: To ensure the strongest, most durable and cleanest welds possible, perform testing before and during all weld procedures. Always follow American Weld Society specifications and procedures.

Note: Diagrams do not show all of the parts.

Explanation of Manual Contents...........

Front Floor............................................

Front Ladder.........................................

Engine Box...........................................

RR Floor & Ladder................................

Misc. Body............................................

Underbody-48.......................................

BSA-48.................................................

BSA-49.................................................

Front Door............................................

RR Door................................................

Liftgate..................................................

Dash/Cowl............................................

Frt Ladder,Rails, & Wheelhouse............

Engine Box Ass'y...................................

RR Ladder Ass'y....................................

RR Ladder & Floor Ass'y........................

Underbody Framing Ass'y.......................

Underbody Complete..............................

BSA Outer-48 Ass'y................................

Framed BIW-48 Ass'y.............................

Framed Full BIW-48 Ass'y......................

BSA Outer-49 Ass'y................................

Framed BIW-49 Ass'y.............................

Framed Full BIW-49 Ass'y

..................

Back To Index

Explanation of Welding/Sealer Information

The major construction of a unibody vehicle consists of welded panels that create the supporting structure for all componets and assemblies of the vehicle. Here are some examples for replacement of these parts.

Certain body components must use sealers to ensure proper assembly. Be sure to check the Body Sealing Locations and Structural Adhesive Sections for location and sealer type.

SEALER LEGEND

Thumbgrade Sealer

Pumpable Sealer

Hidden Sealer

Non Structural Expand Foam

The welded componets are indicated

by using the designations given in

the illustration below: For example,

"AB to AA" indicates that component

"AB" and component "AA" shown in this illustration are welded together.

1. AB TO AA 5/SD S/WELD

2. AC TO AA 3/SD S/WELD

Part I.D.

AC= Fender Bracket

Part I.D.

(AB TO AA)

AB= Fender Bracket

AA= Fender

Weld Attachment Location (AB TO AA) 5 Standard Spot Welds (5/SD S/WELD)

Part I.D.

(AC TO AA)

AA= Fender

Part Assembly I.D.

(Part Number 9803)

Weld Number I.D.

14 = Weld I.D.

R = right side

Back To Index

PARTS IDENTIFICATION LEGEND, OVERVIEW 2

AA EXTENSION - TUNNEL - AH CROSSMEMBER - FRT SEAT FRT LT AB REINF - TUNNEL - AJ EXTENSION - RAIL FRT RT AC PANEL - FRT FLOOR PAN TUNNEL CTR - AK REINF - RAIL TO TUNNEL RT AD PANEL - FRT FLOOR PAN RT - AK REINF - RAIL TO TUNNEL LT AD PANEL - FRT FLOOR PAN LT - AL BRACKET - TRANS MOUNTING RT AE CROSSMEMBER - FRT SEAT RR RT - AL BRACKET - TRANS MOUNTING LT AE CROSSMEMBER - FRT SEAT RR LT - AM STUD.WELD/EXTERNAL - HEADER.PT.SPECIAL - HEAT

SHIELD ATTACH

AF STUD PLATE - CTR TUNNEL BRACE RT - AN STUD.WELD/INTERNAL - HEADER.PT.NO.FIN.ROUND -

STUD PLATE ATTACH AF STUD PLATE - CTR TUNNEL BRACE LT - AP REINF - I/P BRACKET RT AG BRACKET - CTR BEARING MOUNTING RT - AP REINF - I/P BRACKET LT AG BRACKET - CTR BEARING MOUNTING LT - AR NUT/WELD.HEX - NO.FIN - I/P ATTACH AH CROSSMEMBER - FRT SEAT FRT RT -

Back To Index

1. AB TO AA 33 S/WELD

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2. AB TO AA 2 S/WELD

3. AC TO AB 27 S/WELD

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4. AE TO AD TO AC 2 S/WELD

5. AE TO AC 6 S/WELD

6. AE TO AD 17 S/WELD

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7. AG TO AF 22 S/WELD

8. AE TO AD TO AC 2 S/WELD

9. AE TO AC 6 S/WELD

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10. AG TO AE TO AC 3 S/WELD

11. AG TO AC 3 S/WELD

12. AF TO AD 2 S/WELD

13. AF TO AE TO AD 4 S/WELD

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14. AF TO AE TO AD 4 S/WELD

15. AG TO AE TO AC 3 S/WELD

16. AG TO AC TO AB 2 S/WELD

17. AG TO AC 1 S/WELD

18. AF TO AD 2 S/WELD

Back To Index

19. AC TO AA 19 S/WELD

20. AD TO AC TO AA 1 S/WELD

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21. AH TO AA 8 S/WELD

22. AH TO AD 10 S/WELD

23. AH TO AD TO AA 1 S/WELD

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24. AH TO AA 4 S/WELD

25. AH TO AD TO AA 1 S/WELD

26. AH TO AD 11 S/WELD

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27. AH TO AD TO AA 1 S/WELD

28. AH TO AA 5 S/WELD

29. AH TO AD 10 S/WELD

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30. AH TO AD 12 S/WELD

31. AH TO AA 4 S/WELD

32. AH TO AD TO AA 1 S/WELD

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33. AJ TO AH TO AD 1 S/WELD

34. AJ TO AD 14 S/WELD

35. AJ TO AH 2 S/WELD

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36. AK TO AD TO AA 5 S/WELD

37. AJ TO AD 6 S/WELD

38. AK TO AD 8 S/WELD

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39. AJ TO AH 3 S/WELD

40. AJ TO AD 15 S/WELD

41. AK TO AJ TO AD 6 S/WELD

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42. AK TO AD 14 S/WELD

43. AL TO AK TO AD 5 S/WELD

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44. AF TO AD TO AC 3 S/WELD

45. AD TO AA 10 S/WELD

46. AD TO AC 10 S/WELD

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47. AD TO AA 14 S/WELD

48. AF TO AD TO AC 3 S/WELD

49. AD TO AC 11 S/WELD

50. AD TO AC TO AA 1 S/WELD

Back To Index

51. AL TO AA 17R 9L S/WELD

52. AL TO AD TO AA 2 S/WELD

53. AL TO AD 7 S/WELD

Back To Index

54. AM TO AA 2 PROJ WELD

55. AM TO AC 2 PROJ WELD

56. AM TO AD 7 PROJ WELD

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57. AM TO AD 9 PROJ WELD

58. AM TO AA 1 PROJ WELD

59. AM TO AC 2 PROJ WELD

Back To Index

PARTS IDENTIFICATION LEGEND, OVERVIEW 3

AA PANEL - TOEBOARD CROSSMEMBER - AH BRACKET - HEADLAMP MOUNTING LT AB REINF - TOEBOARD CROSSMEMBER INR RT - AJ BRACKET - ENGINE CRADLE MOUNTING LWR FRT RT AB REINF - TOEBOARD CROSSMEMBER INR LT - AJ BRACKET - ENGINE CRADLE MOUNTING LWR FRT LT AC PANEL - EXTENSION FRT RAIL OTR RT - AK BRACKET - ENGINE CRADLE MOUNTING UPR FRT RT AC PANEL - EXTENSION FRT RAIL OTR LT AK BRACKET - ENGINE CRADLE MOUNTING UPR FRT LT AD PANEL - EXTENSION FRT RAIL INR RT AL TAPPING PLATE - FLOATING AD PANEL - EXTENSION FRT RAIL INR LT - AM NUT/WELD.SQ - SQUARE - FRT SIDE RAIL ASSY LT AE BRACKET - ENGINE CRADLE MOUNTING UPR RR RT - AN STUD.WELD/EXTERNAL - HEADER.PT.SPECIAL - DEAD AE BRACKET - ENGINE CRADLE MOUNTING UPR RR LT - PEDAL TRIM PNL ATTACH AF PANEL - FRT SIDE RAIL INR RT - AP PANEL - SHOCK TOWER MOUNTING FRT RT AG REINF - FRT SIDE RAIL BUMPER MOUNTING RT - AR BRACKET - FRT SUSP UPR CONTROL ARM RT AG REINF - FRT SIDE RAIL BUMPER MOUNTING LT - AT REINF - FRT SHOCK TOWER RT AH BRACKET - HEADLAMP MOUNTING RT - AT REINF - SHOCK TOWER TO LOAD BEAM RT - SHOCK

TOWER RH AU PANEL - FRT WHEELHOUSE FRT RT AV PANEL - FRT WHEELHOUSE RR RT -

AX CHARTONLY-NONTORQUE HEADER.PT.LOCK.FEAT.

SPECIAL - SHOCK TOWER GROUND AY NUT/WELD.HEX - NO.FIN - FRT STRUT TWR TO TWR

BEAM ATTACH AZ BRACKET - RETAINER ENGINE CRADLE TAPPING PLATE

FRT BA REINF - RAIL FRT - FRT RAIL

Back To Index

2. AE TO AC 1/SD S/WELD

3. AE TO AD TO AC 2/SD S/WELD

4. AD TO AC 11/SD S/WELD

5. AK TO AJ 4/SD S/WELD

6. AG TO AJ 1/SD S/WELD

7. AK TO AJ TO AG 1/SD S/WELD

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8. AE TO AC TO AF 1/SD S/WELD

9. AE TO AC 7/SD S/WELD

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10. AF TO AD 5/SD S/WELD

11. AF TP AE 6/SD S/WELD

12. AF TO AE TO AD 1/SD S/WELD

13. AE TO AD 2/SD S/WELD

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14. AH TO AF 5/SD S/WELD

15. AG TO AF 6/SD S/WELD

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16. AK TO AJ TO AF 8/SD S/WELD

17. AL TO AF 2/SD S/WELD

18. AK TO AJ 5/SD S/WELD

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19. AM TO AG 4/SD PROJ WELD

20. AM TO AH 1/SD PROJ WELD

21. AN TO AF 1/SD PROJ WELD

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22. AR TO AP 22R/23L S/WELD

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23. AT TO AP 13R/14L S/WELD

24. AS TO AR 4R/2L S/WELD

25. AS TO AP 7/SD S/WELD

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26. AU TO AP 9/SD S/WELD

27. AW TO AP 8/SD S/WELD

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28. AW TO AU 2 PROJ WELD

29. AX TO AP 2/SD PROJ WELD

30. AX TO AU 1 PROJ WELD

31. AY TO AP 2/SD PROJ WELD

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32. BA TO AE 2/SD S/WELD

33. AZ TO AE 7SD PROJ WELD

34. AZ TO AK 7/SD PROJ WELD

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PARTS IDENTIFICATION LEGEND, OVERVIEW 4

AA PANEL - LOAD PATH BEAM UPR INR RT AA PANEL - LOAD PATH BEAM UPR INR LT AB BRACKET - HEADLAMP MOUNTING RT AB BRACKET - HEADLAMP MOUNTING LT AC BRACKET - WIPER MODULE MTG AD NUT/WELD.HEX - NO.FIN - BRKT TO MODULE AE STUD.WELD/INTERNAL - NO.FIN.PILOT.PT - UPR BRAKE PEDAL ATT

AF REINF - BRAKE BOOSTER -

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1. AB TO AA 4/SD S/WELDS

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2. AC TO AD 1 PROJ WELD

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3. AE TO AF 1 PROJ WELD

4. AE TO AF 1 PROJ WELD

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PARTS IDENTIFICATION LEGEND, OVERVIEW 5

AA RAIL - RR INR RT - AM STUD.WELD/INTERNAL - HEADER.PT.NO.FIN.PF- SAFETY AA RAIL - RR INR LT - CENTER SEAT BELT RETRACTOR ATT AB REINF - RR RAIL INR RR RT - AN CROSSMEMBER - RR SUSPENSION FRT AB REINF - RR RAIL INR RR LT - AP TAPPING PLATE AC NUT/WELD.SQ - SQUARE - RAIL ATTACH AR EXTENSION - CROSSMEMBER END SUPPORT RT AD TAPPING PLATE - SEAT BELT RETRACTOR AR EXTENSION - CROSSMEMBER END SUPPORT LT -

ANCHOR RR CTR - AS REINF - CROSSMEMBER RR SUSPENSION MOUNTING RT AE RAIL - RR OTR RT - AS REINF - CROSSMEMBER RR SUSPENSION MOUNTING LT AE RAIL - RR OTR LT - AT BRACKET - RETAINER ENGINE CRADLE TAPPING PLATE FRT AF BRACKET ASSY - CRADLE RT - AU NUT/WELD.SQ - SQUARE - BATTERY TRAY ATTACH AF BRACKET ASSY - CRADLE LT - AV PAN - RR FLOOR AG TAPPING PLATE - SEAT BELT RETRACTOR AW REINF - SPARE TIRE HOLD-DOWN -

ANCHOR RR CTR - AX GUSSET - ISO FIX AH REINF - RR RAIL OTR RT - AY STUD.WELD/INTERNAL - HEADER.PT.NO.FIN.PF-SAFETY - CTR AH REINF - RR RAIL OTR LT - RR RETRACTOR ATTACH AJ BRACKET - CRADLE ATTACHING RT - AZ CROSSMEMBER - ISO FIX AJ BRACKET - CRADLE ATTACHING LT - BA WIRE - ISO FIX - RIGHT AK BRACKET - RETAINER ENGINE CRADLE BA WIRE - ISO FIX - LEFT

TAPPING PLATE FRT - BB WIRE - ISO FIX - CENTER AL REINF - SEAT BELT ANCHOR RR INBOARD -

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1. AB TO AA 16R & 12L S/WELDS

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2. AB TO AA 16R & 9L S/WELDS

3. AC TO AA 2 PROJ WELDS

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4. AB TO AA 8L S/WELDS

5. AD TO AB 4L S/WELDS

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6. AF TO AE 7/SD S/WELDS

7. AG TO AE 2/SD S/WELDS

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8. AH TO AE 24/SD S/WELDS

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9. AH TO AE 5/SD S/WELDS

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10. AK TO AJ 4/SD S/WELDS

11. AM TO AL 1 PROJ WELD

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12. AP TO AN 2/SD S/WELDS

13. AS TO AR 6/SD S/WELDS

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14. AR TO AN 9/SD S/WELDS

15. AT TO AS 4/SD S/WELDS

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16. AU TO AV 2 PROJ WELDS

17. AW TO AV 10 S/WELDS

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18. AY TO AX 4/SD PROJ WELDS

19. AZ TO AX 4/SD S/WELDS

20. BA TO AZ 4 FCAW WELDS

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21. BB TO AX 2/SD FCAW WELDS

22. BC TO AZ 16 FCAW WELDS

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PARTS INDENTIFICATION LEGEND, OVERVIEW 6

AA PANEL - ROOF SUNROOF - AH EXTENSION - IMPACT BEAM FRT DOOR RR RT AB PANEL - ROOF OTR - AH EXTENSION - IMPACT BEAM FRT DOOR RR LT AC PANEL - ROOF SUNROOF - AJ EXTENSION - RR DOOR IMPACT BAR RR RT AD REINF - SUNROOF - AJ EXTENSION - RR DOOR IMPACT BAR RR LT AE BAR - IMPACT FRT DOOR RT - AK EXTENSION - RR DOOR IMPACT BAR FRT RT AE BAR - IMPACT FRT DOOR LT - AK EXTENSION - RR DOOR IMPACT BAR FRT LT AF BAR - IMPACT RR DOOR RT - AL REINF - PLATE AF BAR - IMPACT RR DOOR LT - AL REINF - PLATE - ROOF RACK REAR AG EXTENSION - IMPACT BEAM FRT DOOR FRT RT - AM NUT/WELD.HEX - HEX.DRIVE.SPECIAL AG EXTENSION - IMPACT BEAM FRT DOOR FRT LT - SUNROOF MODULE

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