2005 Chrysler 300 Dodge Magnum LX Body Service & Repair Manual

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. Back To Index

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 Back To Index

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 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...................... 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............................

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. Back To Index

Back To Index CHRYSLER 300, 300C, 300 TOURING, & DODGE MAGNUM COMPONENT CHART PART SPECIFICATION LIST CAR LINE CHART A C D D MIN PART L 4 4 4 PART GAGE # L 8 8 9 DESCRIPTION METRIC MATERIAL 4 C TROUGH - DECK OPENING SIDE RT 1.24 MS-6000 44A C TROUGH - DECK OPENING SIDE LT 4 8 TROUGH - DECK OPENING SIDE RT 1.24 MS-6000 44A 8 TROUGH - DECK OPENING SIDE LT 4 D TROUGH - QTR PANEL DRAIN UPR RT 1.52 MS-6000 44VA-040SK D TROUGH - QTR PANEL DRAIN UPR LT 7 A BRACKET - FRT SUSP UPR CONTROL ARM R 1.98 MS-6000 44VA-050XK A BRACKET - FRT SUSP UPR CONTROL ARM L 9 A PANEL - RR WHEELHOUSE INR RT 1.22 MS-6000 44A A PANEL - RR WHEELHOUSE INR LT 10 A REINFORCEMENT - SILL FRT RT 0.99 MS-6000 44VA-050-XF A REINFORCEMENT - SILL FRT LT 12 A PANEL - RR WHEELHOUSE OTR RT 0.61 MS-6000 44A A PANEL - RR WHEELHOUSE OTR LT 13 C PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK C PANEL - BODY SIDE INR LT

Back To Index CHRYSLER 300, 300C, 300 TOURING, & DODGE MAGNUM COMPONENT CHART PART SPECIFICATION LIST 13 8 PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK 8 PANEL - BODY SIDE INR LT 13 D PANEL - BODY SIDE INR RT 1.42 MS-6000 44VA-050-XK D PANEL - BODY SIDE INR LT 15 C PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE C PANEL - BODY SIDE OTR LT 15 8 PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE 8 PANEL - BODY SIDE OTR LT 15 D PANEL - BODY SIDE OTR RT 0.79 MS-6000 44AE D PANEL - BODY SIDE OTR LT 17 A PANEL - RR SHOCK MOUNTING RT 2.00 MS-6000 44VA-050-XK A PANEL - RR SHOCK MOUNTING LT 18 A TAPPING PLATE - DOOR HINGE FRT RT 2.40 MS-66 A TAPPING PLATE - DOOR HINGE FRT LT 18 A TAPPING PLATE - DOOR HINGE FRT LT 2.40 MS-66 23 A BRACKET - ENGINE CRADLE MOUNTING UPR 1.80 MS-6000 44VA-050-XK A BRACKET - ENGINE CRADLE MOUNTING UPR 25 A REINFORCEMENT - TOEBOARD CROSSMEMBER 1.98 MS-6000 44VA-080-XK A REINFORCEMENT - TOEBOARD CROSSMEMBER 26 A PANEL - UPR LOAD PATH OTR RT 0.89 MS-6000 44VA-050-XK A PANEL - UPR LOAD PATH OTR LT

Back To Index CHRYSLER 300, 300C, 300 TOURING, & DODGE MAGNUM COMPONENT CHART PART SPECIFICATION LIST 27 A BRACKET - ENGINE CRADLE MOUNTING UPR 1.47 MS-6000 44VA-050-XK 28 A SPACER - BRAKE BOOSTER 3.50 MS - 588 -B - 3 31 A PANEL - SHOCK TOWER MOUNTING FRT RT 2.08 MS-6000 44A A PANEL - SHOCK TOWER MOUNTING FRT LT 32 A PANEL - FRT WHEELHOUSE RR RT 0.76 MS-6000 44A A PANEL - FRT WHEELHOUSE RR LT 33 D PANEL - HOOD INR 0.90 MS-8580 A96022-T43 C PANEL - HOOD INR 8 PANEL - HOOD INR 34 D PANEL - HOOD OTR 0.90 MS-8580 A96022-T4E29 C PANEL - HOOD OTR 8 PANEL - HOOD OTR 35 A TAPPING PLATE - HOOD INR PANEL HINGE 2.00 MS-8580 A96022-T4 A TAPPING PLATE - HOOD INR PANEL HINGE 36 C CROSSMEMBER - HEADLAMP MOUNTING MS-DB-41/MS-6000 44VA D CROSSMEMBER - HEADLAMP MOUNTING 8 CROSSMEMBER - HEADLAMP MOUNTING 38 A PAN - TORQUE BOX RT 2.50 MSDB543,CPN2194,TYPEA 39 A PANEL - FRT WHEELHOUSE FRT RT 1.42 MS-6000 44VA-050 A PANEL - FRT WHEELHOUSE FRT LT 41 A TAP PLATE - FLOATING 1.98 MS-66 44 A PANEL - LWR RADIATOR CROSSMEMBER 0.79 MS-67

Back To Index CHRYSLER 300, 300C, 300 TOURING, & DODGE MAGNUM COMPONENT CHART PART SPECIFICATION LIST 49 C REINF - HOOD INR PANEL SLAM 1.25 MS-8580 A96022-T4 D REINFORCEMENT - HOOD INR PANEL SLAM 8 REINFORCEMENT - HOOD INR PANEL SLAM 51 A PANEL - RAIL FRT COVER RT 1.54 MS-6000 44VA-590DT A PANEL - RAIL FRT COVER LT 53 A PANEL - FRT SIDE RAIL INR RT 1.54 MS-6000 44VA-590DT A PANEL - FRT SIDE RAIL INR LT 54 A PANEL - COWL LWR 0.89 MS-6000 44A 55 A BRACKET - ICU 1.47 MS-6000 44A 56 A PANEL - COWL UPR 0.71 MS-6000 44A 58 A PANEL - DASH 0.71 MS-6000 44A 62 A PANEL - EXTENSION FRT RAIL OTR RT 1.98 MS-6000 44VA-050-XK A PANEL - EXTENSION FRT RAIL OTR LT 63 A PANEL - EXTENSION FRT RAIL INR RT 1.88 MS-6000 44VA-050-XK A PANEL - EXTENSION FRT RAIL INR LT 64 A SHIELD - SPLASH RR WHEELHOUSE RT 2.00 MSDB-543,TYPE A A SHIELD - SPLASH RR WHEELHOUSE LT 65 A REINF - RAIL TO TUNNEL RT 1.04 MS-264 035-SK A REINF - RAIL TO TUNNEL LT 66 A COVER PLATE - RAIL RR RT 1.24 MS-6000 44VA-050-XK A COVER PLATE - RAIL RR LT

Back To Index CHRYSLER 300, 300C, 300 TOURING, & DODGE MAGNUM COMPONENT CHART PART SPECIFICATION LIST 67 A ROD ASSY - HOOD SUPPORT 8.00 MS-284 68 A REINF - TUNNEL 1.19 MS-264 050-XF 69 A EXTENSION - RAIL FRT RT 1.40 MS-264 050-XK A EXTENSION - RAIL FRT LT 70 A PANEL - FRT FLOOR PAN TUNNEL CTR 0.89 MS-6000 44VA-050-XF 71 A TAPPING PLATE - HINGE BODY 1.27 MS-6000 72 A REINF - I/P BRACKET RT 2.00 MS-66 A REINF - I/P BRACKET LT 73 A PANEL - LOAD PATH BEAM UPR INR RT 0.89 MS-6000 44VA-050-XF A PANEL - LOAD PATH BEAM UPR INR LT 76 A RETAINER - RR DOOR STRIKER RT 1.52 MS-66 A RETAINER - RR DOOR STRIKER LT 77 A CROSSMEMBER - ISOFIX 1.50 MS-264 050-XK 78 A GLASS ASSY - WINDSHIELD 5.10 MS-10472-B 79 C PANEL - ROOF OTR 0.74 MS-67 8 PANEL - ROOF OTR D PANEL - ROOF OTR D PANEL - ROOF OTR 80 A REINF - HOOD INR PANEL STRIKER 2.00 MS-8580 A96022-T4

2005 Chrysler 300 Dodge Magnum LX Body Service & Repair Manual

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