Dodge Durango (DN). Manual — part 7

replacement bolts that are used to join the frame
members should conform to the same specifications
as the original bolts.

FRAME REPAIRS

DRILLING HOLES

Do not drill holes in frame side rail top and bottom

flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.

Additional drill holes should be located away from

existing holes.

WELDING

Use MIG, TIG or arc welding equipment to repair

welded frame components.

Frame components that have been damaged should

be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.

(1) Drill a hole at each end of the crack with a 3

mm (O.125 in.) diameter drill bit.

(2) Using a suitable die grinder with 3 inch cut off

wheel, V-groove the crack to allow 100% weld pene-
tration.

(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind

the weld smooth and install a reinforcement channel
(Fig. 1) over the repaired area.

NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 1).

FRAME FASTENERS

Bolts, nuts and rivets can be used to repair frames

or to install a reinforcement section on the frame.

Conical-type washers are preferred over the split-

ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair. Grade-3 bolts or softer
should not be used. Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.

REMOVAL AND INSTALLATION

FRONT AXLE SKID PLATE

REMOVAL

(1) Position a support under skid plate.
(2) Remove bolts attaching skid plate to front

crossmember (Fig. 2).

(3) Remove bolts attaching skid plate to skid plate

crossmember (Fig. 3).

(4) Separate skid plate from the vehicle.

INSTALLATION

(1) Position and support skid plate at front cross-

member.

(2) Install bolts attaching skid plate to transmis-

sion crossmember. Tighten to 23 N·m (17 ft. lbs.)
torque.

(3) Install bolts attaching skid plate to front cross-

member. Tighten to 23 N·m (17 ft. lbs.) torque.

(4) Remove support from under skid plate.

Fig. 1 Frame Reinforcement

1 – .250 IN FROM EDGE
2 – TOP FLANGE
3 – BOTTOM FLANGE
4 – FRAME RAIL
5 – FRAME REPAIR REINFORCEMENT

Fig. 2 Front Axle Skid Plate

1 – U-NUT
2 – FRAME
3 – SKID PLATE

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FRAME AND BUMPERS

DN

SERVICE PROCEDURES (Continued)

TRANSFER CASE SKID PLATE

REMOVAL

(1) Hoist and support vehicle on safety stands.
(2) Remove bolts attaching skid plate to crossmem-

bers (Fig. 4).

(3) Separate skid plate from vehicle.

INSTALLATION

(1) Position skid plate on vehicle.
(2) Install bolts attaching skid plate to crossmem-

bers. Tighten to 23 N·m (17 ft. lbs.) torque.

(3) Remove safety stands and lower vehicle.

FUEL TANK SKID PLATE—4WD VEHICLES

REMOVAL

(1) Position a support under skid plate.
(2) Remove inboard screws that attach skid plate

to crossmember.

(3) Remove bolts that attach skid plate to frame

side rail (Fig. 5).

(4) Remove support and skid plate from vehicle.

INSTALLATION

(1) Position and support skid plate under fuel

tank.

(2) Install inboard screws attaching skid plate to

crossmember. Tighten screws to 41 N·m (30 ft. lbs.)
torque.

(3) Install bolts attaching skid plate to frame side

rail. Tighten bolts to 23 N·m (17 ft. lbs.) torque.

(4) Remove support from under skid plate.

SPARE TIRE WINCH

CAUTION: Do not use impact wrench when winch-
ing spare tire.

Fig. 3 Front Axle Skid Plate

1 – U-NUT
2 – BRACKET
3 – SKID PLATE CROSSMEMBER
4 – SKID PLATE

Fig. 4 Transfer Case Skid Plate

1 – U—NUT
2 – U—NUT
3 – FRAME
4 – SKID PLATE

Fig. 5 Fuel Tank Skid Plate—4WD Vehicles

1 – FRAME
2 – SKID PLATE
3 – SCREW
4 – SCREW
5 – RIV—NUT
6 – RIV—NUT

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FRAME AND BUMPERS

13 - 7

REMOVAL AND INSTALLATION (Continued)

REMOVAL

(1) Remove spare tire.
(2) Raise and support vehicle on hoist.
(3) Remove bolts attaching spare tire winch to

frame.

INSTALLATION

(1) Position spare tire winch on frame and install

bolts. Tighten bolts to 18 N·m (13 ft. lbs.) torque.

(2) Remove support and lower vehicle.
(3) Install spare tire.

TRAILER HITCH

REMOVAL

(1) Remover spare tire.
(2) Support trailer hitch on a suitable lifting

device.

(3) Remove fasteners attaching trailer wiring con-

nector to trailer hitch, if equipped (Fig. 7).

(4) Remove bolts attaching trailer hitch to frame

rails and rear crossmember (Fig. 8).

(5) Separate trailer hitch from vehicle.

INSTALLATION

(1) Position trailer hitch on vehicle.
(2) Install the bolts attaching trailer hitch to

frame rail and rear crossmember. Tighten bolts to
108 N·m (80 ft. lbs.) torque.

(3) Install fasteners attaching trailer wiring con-

nector to trailer hitch, if equipped.

(4) Install spare tire.

SPECIFICATIONS

FRAME DIMENSIONS

FRAME

All dimensions are listed in millimeters.

Fig. 6 Spare Tire Winch

1 – FRAME
2 – SPARE TIRE WINCH

Fig. 7 Trailer Hitch Harness Connector

1 – TRAILER HARNESS CONNECTOR
2 – HARNESS CONNECTOR

Fig. 8 Trailer Hitch

1 – FLAG BOLT
2 – SPRING WASHER
3 – TRAILER HITCH
4 – FRAME

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FRAME AND BUMPERS

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REMOVAL AND INSTALLATION (Continued)

DN

FRAME AND BUMPERS

13 - 9

SPECIFICATIONS (Continued)