1. Equipment and Tool Institute June 18, 2008 2009 Challenger Body Structure Diane Coopmans, Body Structures Engineering

2. June 18, 2008Diane Coopmans, Body Structures Engineering2 2009 Challenger versus Charger / 300 What has changed? Multi-piece body side reinforcement assembly with Boron steel upper A-pillar reinforcement and enclosed A- pillar tube structure for roof strength. Boron steel AHSS

3. June 18, 2008Diane Coopmans, Body Structures Engineering3 2009 Challenger versus Charger / 300 What has changed? Body side inner extension welds to rear close out panel. Sill reinforcements extend from A-pillar back to rear wheel opening. Body side inner extension Sill Reinforcements

4. June 18, 2008Diane Coopmans, Body Structures Engineering4 2009 Challenger versus Charger / 300 What has changed? Cross-car beam with bolt-on extensions for side impact is located at the rear kick-up, behind the door opening. Body Side Gusset Beam Extension Cross-car Beam

5. June 18, 2008Diane Coopmans, Body Structures Engineering5 2009 Challenger versus Charger / 300 What has changed? Front seat belts have fixed turning loops and sliding lower anchorages. Turning loop is part of retractor assy Body reinforcement Lower anchorage

6. June 18, 2008Diane Coopmans, Body Structures Engineering6 2009 Challenger versus Charger / 300 What has changed? Floor pan modified for 116-inch wheelbase and manual / automatic transmission option. Charger / 300 Challenger Shifter closeout panel Shortened 4 inches

7. June 18, 2008Diane Coopmans, Body Structures Engineering7 2009 Challenger versus Charger / 300 What has changed? Rear rails have an additional reinforcement near rear cradle attachment for manual transmission durability. Rail Reinforcement

8. June 18, 2008Diane Coopmans, Body Structures Engineering8 2009 Challenger versus Charger / 300 What has changed? Front Bumper Beam has bolt-on AHSS Extensions in addition to the LX-type Energy Absorber (EA). Extension EA Headlamp mounting cross member

9. June 18, 2008Diane Coopmans, Body Structures Engineering9 2009 Challenger versus Charger / 300 What has changed? Front fascia is attached to the fenders via brackets and is supported by a grill surround attached to the headlamp mounting cross member. Fascia brackets Grill surround Headlamp mounting cross member

10. June 18, 2008Diane Coopmans, Body Structures Engineering10 2009 Challenger versus Charger / 300 What has changed? Rear fascia is attached to the body sides via brackets. The rear bumper beam is modified for exhaust clearance. Beam modification Fascia brackets Energy Absorber

11. June 18, 2008Diane Coopmans, Body Structures Engineering11 2009 Challenger versus Charger / 300 What has changed? Side doors are conventional build-up with hardtop glass, door-mounted mirrors and Boron steel impact beams. Mirror attaches to outer belt reinforcement. Boron steel

12. June 18, 2008Diane Coopmans, Body Structures Engineering12 2009 Challenger versus Charger / 300 What has changed? Side doors with hardtop glass require special processing to prevent wind noise and water leaks. Encapsulated quarter glass Hardtop door glass Body mounted seal / retainer

13. June 18, 2008Diane Coopmans, Body Structures Engineering13 2009 Challenger versus Charger / 300 Some Engineering Recommendations for Door Repair or Rebuild: Replace the window regulator assembly if there is visible damage to the guide rails. Replace any bent linkage rods: – Door handle (inside and outside) links to the latch, – Inside lock knob to latch, – Key cylinder link to latch on driver’s side. Follow recommended procedure for door glass replacement or adjustment: –Replace glass clamp screws, –With the door trim removed, set the glass to the new body mounted seal and quarter window by tightening the glass clamp screws. (See instructions and picture for details.) Replace door glass and body seals (See picture for details): –Due to seal set and break in, seals should be replaced if door or glass is changed. This includes the body mounted glass seals and door primary glass-run channel.

14. June 18, 2008Diane Coopmans, Body Structures Engineering14 2009 Challenger versus Charger / 300 Recommended Glass Setting Instructions: Make sure that: - the door trim is removed, - the glass is in the clamps, - the glass clamp screws are loose (window must be free to move), - the window regulator is run to it’s full-up position, Place masking tape over the glass edge, in two places, and strike a mark, on both pieces of tape, 8 mm’s from the top edge of glass. Then, with one person inside the vehicle, a second person will lift the door glass up into the body seal (hands flat on the glass with rubber gloves works best) and line up the marks on the tape with the outer seal lip. Press on the glass with both hands until the door glass is under-flush to the quarter window by a few millimeters. (There will be spring-back in the glass once the glass clamp screws are tightened and pressure is released off the door glass.) Also make sure that the door glass is parallel, with a 6 mm gap, to the quarter window. Next, have the operator, inside the vehicle, tighten the glass clamp screws to their proper torque values. The outside operator can then let go of the glass. If the door glass is over-flush to the quarter window, loosen the glass clamp screws, push on door glass and repeat the tightening process until the glass is flush.

15. June 18, 2008Diane Coopmans, Body Structures Engineering15 2009 Challenger versus Charger / 300 Dual rail window regulator assembly Guide Rails Door primary seal (orange) Body mounted glass seal (orange) Encapsulated quarter window Door inner and outer belt seals

16. June 18, 2008Diane Coopmans, Body Structures Engineering16 2009 Challenger versus Charger / 300 Glass Clamp Glass Clamp Screw (Replace for Service)

17. June 18, 2008Diane Coopmans, Body Structures Engineering17 2009 Challenger versus Charger / 300 Glass Engagement Zone: (Glass Engagement into the Body Seal = 8mm +/-2) Gap/Parallel Check Zone (Dr Glass to Qtr Window) Set Door Glass 6mm to Qtr Window Gap Tolerance = +/-2 Door Glass Flush Zone (Flushness to Qtr Window) Over-flush = 0 mm Under-flush = -3 mm (max) Tape & rough locations

18. June 18, 2008Diane Coopmans, Body Structures Engineering18 2009 Challenger versus Charger / 300 What has not changed? Front body structure maintains common rails, toeboard cross member, cradle attachments, wheelhouses and shock towers. Front bumper beam is modified. Rear body structure uses common floor, rails, cradle attachments and cross members, except for addition of rail reinforcements as noted. Rear bumper beam is modified. Rear seat and belt attachments are similar to Charger and 300.