equipment and tool institute june 18, 2008 2009 challenger body structure diane coopmans, body...
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Equipment and Tool InstituteJune 18, 2008
2009 Challenger Body Structure
Diane Coopmans, Body Structures Engineering
June 18, 2008 Diane Coopmans, Body Structures Engineering 2
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 steelAHSS
June 18, 2008 Diane Coopmans, Body Structures Engineering 3
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 4
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 5
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 6
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 7
2009 Challenger versus Charger / 300
What has changed?• Rear rails have an additional reinforcement near rear
cradle attachment for manual transmission durability.
Rail Reinforcement
June 18, 2008 Diane Coopmans, Body Structures Engineering 8
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).
ExtensionEA
Headlamp mounting cross member
June 18, 2008 Diane Coopmans, Body Structures Engineering 9
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 surroundHeadlamp mounting cross member
June 18, 2008 Diane Coopmans, Body Structures Engineering 10
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 11
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 12
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 glassBody mounted seal / retainer
June 18, 2008 Diane Coopmans, Body Structures Engineering 13
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.
June 18, 2008 Diane Coopmans, Body Structures Engineering 14
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.
June 18, 2008 Diane Coopmans, Body Structures Engineering 15
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
June 18, 2008 Diane Coopmans, Body Structures Engineering 16
2009 Challenger versus Charger / 300
Glass ClampGlass Clamp Screw(Replace for Service)
June 18, 2008 Diane Coopmans, Body Structures Engineering 17
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 WindowGap Tolerance = +/-2
Door Glass Flush Zone(Flushness to Qtr Window)Over-flush = 0 mmUnder-flush = -3 mm (max)
Tape & rough locations
June 18, 2008 Diane Coopmans, Body Structures Engineering 18
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.