equipment and tool institute june 18, 2008 2009 challenger body structure diane coopmans, body...

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



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



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



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



What has changed?• Floor pan modified for 116-inch wheelbase and manual /

automatic transmission option.

Charger / 300 Challenger

Shifter closeout panel

Shortened 4 inches



What has changed?• Rear rails have an additional reinforcement near rear

cradle attachment for manual transmission durability.

Rail Reinforcement



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



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



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



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



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



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.



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.



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



Glass ClampGlass Clamp Screw(Replace for Service)



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



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.

equipment and tool institute june 18, 2008 2009 challenger body structure diane coopmans, body...

Documents

inches2009 challenger

door glass replacement

door primary glass

body mounted glass seals

cross member2009 challenger

hardtop glass

boron steel2009 challenger

body seals