Chrysler 300 300c 300 Touring Dodge Magnum Body Repair Manual.pdf

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 E-

Clips, 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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MANUFACTURER ADVERTISEMENTS

(CLICK ON LINKS )

• 3M

• AKZO-NOBEL

• BASF

• DAIMLERCHRYSLER PAINT CONDITION DECK-SEALER/SOUND

DEADNER REPAIR GUIDE

• LORD CORPORATION

• MOPAR PARTS

• PPG

• TEAM PSE-PENTASTAR SERVICE EQUIPMENT

• TECH AUTHORITY

• VALSPAR

• DAIMLERCHRYSLER PLASTIC REPAIR GUIDE – WELDING & WELD

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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