Dodge Durango (DN). Manual — part 6
FRONT BUMPER INNER BRACKET
REMOVAL
(1) Remove bolts attaching top of bumper to
bumper bracket.
(2) Remove nuts attaching inner bumper bracket
to frame (Fig. 1).
(3) Using a shallow socket and extension or equiv-
alent, tap with a hammer to drive inner bumper
bracket studs out of frame.
(4) Separate inner bumper bracket from frame.
INSTALLATION
(1) Position
inner
bumper
bracket
studs
into
frame.
(2) Install nuts attaching inner bumper bracket to
frame. Tighten nuts to 94 N·m (70 ft. lbs.) torque.
(3) Install bolts attaching top of bumper to bumper
bracket.
FRONT BUMPER FASCIA
REMOVAL
(1) Remove the front bumper.
(2) Remove the bolts attaching the fascia to the
bumper.
(3) Separate fascia from bumper.
INSTALLATION
(1) Position fascia on bumper.
(2) Install the bolts attaching the fascia to the
bumper.
(3) Install the front bumper.
REAR BUMPER
REMOVAL
(1) Remove trailer hitch, if equipped.
(2) Raise and support the rear of the vehicle.
(3) Support the bumper.
(4) Remove rivets at each side rear wheel well.
(5) Disconnect license plate lamp wiring harness.
(6) Remove nuts attaching bumper support brack-
ets to rear rails and crossmember (Fig. 2).
(7) Remove the bumper/fascia from the vehicle.
INSTALLATION
(1) Position the bumper/fascia on the vehicle.
Fig. 1 Front Bumper
1 – FOG LAMP
2 – FRONT BUMPER
3 – OUTER BUMPER BRACKET
4 – U-NUT
5 – FRAME
6 – INNER BUMPER BRACKET
7 – FASCIA BRACKET
13 - 2
FRAME AND BUMPERS
DN
REMOVAL AND INSTALLATION (Continued)
(2) Install nuts attaching bumper support brackets
to crossmember and rear rails (Fig. 2).
(3) Check
gaps
and
fit. Adjust
as
necessary.
Tighten nuts to 54 N·m (40 ft. lbs.) torque.
(4) Connect license plate lamp wiring harness.
(5) If equipped, install the trailer hitch.
REAR BUMPER FASCIA
REMOVAL
(1) Remove rivets at each side rear wheel well.
NOTE: Removing the step pad will damage the step
pad retainers, verify availability of step pad from
parts supplier.
(2) Using a trim stick, carefully pry step pad from
fascia.
(3) Disconnect license plate lamp connector.
(4) Remove upper push pin from the bumper fascia
(Fig. 3).
(5) Remove the lower push pins from the bumper
fascia.
Fig. 2 Rear Bumper
1 – BUMPER BEAM
2 – PUSH—PIN
3 – STEP PAD
4 – PUSH—PIN
5 – PUSH—PIN
6 – FASCIA
7 – SHIELD
8 – BLIND RIVET
9 – FASCIA BRACKET
10 – BUMPER BRACKET
11 – FRAME
DN
FRAME AND BUMPERS
13 - 3
REMOVAL AND INSTALLATION (Continued)
(6) Remove the bumper fascia from the bumper
(Fig. 2).
INSTALLATION
(1) Position the bumper fascia on the bumper (Fig.
2).
(2) Install upper push pin.
(3) Align all holes and install the lower push pins.
(4) Position step pad on fascia and press into
place.
(5) Connect license plate lamp connector.
(6) Align fascia bracket, wheel house liner shield
and fascia holes and install rivets.
Fig. 3 Rear Fascia
1 – LICENSE PLATE LAMP CONNECTOR
2 – FASCIA
3 – PUSH PIN
4 – RIVET
5 – PUSH PIN
6 – RIVET
13 - 4
FRAME AND BUMPERS
DN
REMOVAL AND INSTALLATION (Continued)
FRAME
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
FRONT AXLE SKID PLATE. . . . . . . . . . . . . . . . . . . 6
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . . 7
FUEL TANK SKID PLATE—4WD VEHICLES . . . . . . 7
SPARE TIRE WINCH . . . . . . . . . . . . . . . . . . . . . . . 7
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 10
DESCRIPTION AND OPERATION
FRAME
DESCRIPTION
The DN uses a three section frame design. The
ends of the center section are swaged to fit into the
front and rear sections. The front, center, and rear
sections are welded together. The frame is serviced
as a complete unit only.
OPERATION
The frame is designed to absorb and dissipate flex-
ing and twisting due to acceleration, braking, corner-
ing and road surface variances without bending when
subjected to normal driving conditions. The frame is
the mounting platform for the following systems and
components:
• Engine, transmission, and transfer case.
• Exhaust system and heat shields.
• Front and rear bumper systems.
• Front and rear suspension systems.
• Front end sheet metal and radiator closure
panel.
• Fuel cell and fuel line tubing.
• Parking brake.
• Steering gear and linkage.
• Skid plate.
• Spare tire winch.
• Trailer hitch.
• Vehicle body.
SERVICE PROCEDURES
FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE
OR
EXPLOSION
CAN
RESULT.
WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE 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.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566°C (1050°F).
The metal will have a dull red glow at the desired
temperature.
Excessive
heat
will
decrease
the
strength of the metal and result in a weakened
frame.
A straightening repair process should be limited to
frame members that are not severely damaged. The
DN
FRAME AND BUMPERS
13 - 5
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