Frame

Chrysler Group LLC engineering’s position on the use of heat during collision repair is as follows:

• Any body panel or frame component damaged which is to be repaired and reused, must be repaired using the “cold straightening” method. No heat may be used during the straightening process.
• During rough straightening prior to panel replacement, damaged panels or frame components may be heated to assist in body/frame realignment. The application of heat must be constrained to the parts which will be replaced and not allowed to affect any other components.

This “no heat” recommendation is due to the extensive use of high strength and advanced high strength steels in Chrysler Group LLC products. High-strength materials can be substantially and negatively affected from heat input which will not be obviously known to the repairer or consumer.

Ignoring these recommendations may lead to serious compromises in the ability to protect occupants in a future collision event, reduce the engineered qualities and attributes, or decrease the durability and reliability of the vehicle.

This statement supersedes any previously released information by the Chrysler Group LLC.

Failure to follow these instructions may result in serious or fatal injury.

Use an Occupational Safety and Health Administration (OSHA) approved breathing filter, when spraying paint or solvents in a confined area. Failure to follow these instructions may result in possible serious or fatal injury.

• avoid prolonged skin contact with petroleum or alcohol based cleaning solvents.
• do not stand under a hoisted vehicle that is not properly supported on safety stands. Failure to follow these instructions may result in possible serious or fatal injury.

When holes are drilled or punched in an inner body panel, verify the depth of space to the outer body panel, electrical wiring or other components. Damage to the vehicle can result.

• do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result.
• always have a fire extinguisher ready for use when welding.
• disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is off. Damage to electrical system can result.
• do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result.
• do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result.
• do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break.

To avoid potential physical injury, or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the ORC capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 30 cm (12 in) of an electronic module/harness, then that module/harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens. Failure to follow these instructions may result in serious or fatal injury.

To avoid serious or fatal injury on vehicles equipped with the Supplemental Restraint System (SRS), never attempt to repair the electrically conductive circuits or wiring components related to the SRS for which there is no MOPAR wiring repair kit. It is important to use ONLY the recommended splicing kit and procedure. For applicable and available MOPAR wiring repair kits, please visit the MOPAR Connector Web Site at the following address on the internet: (http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can compromise the conductivity and current carrying capacity of those critical electrical circuits, which may cause SRS components not to deploy when required, or to deploy when not required. Only minor cuts or abrasions of wire and terminal insulation where the conductive material has not been damaged, or connector insulators where the integrity of the latching and locking mechanisms have not been compromised may be repaired using appropriate methods.

To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar® Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury.

To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, Occupant Classification System (OCS), seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to follow these instructions may result in accidental airbag deployment.

To avoid potential physical injury or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the Occupant Restraint Controller (ORC) capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 12 inches (30 centimeters) of an electronic module or wiring harness, then that module or harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens.

To avoid serious or fatal injury, do not attempt to dismantle an airbag unit or tamper with its inflator. Do not puncture, incinerate or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. An airbag inflator unit may also contain a gas canister pressurized to over 17.24 kPa (2500 psi). Failure to follow these instructions may result in possible serious or fatal injury.

To avoid serious or fatal injury when handling a seat belt tensioner retractor. Exercise proper care to keep fingers out from under the retractor cover and away from the seat belt webbing where it exits from the retractor cover. Failure to follow these instructions may result in possible serious or fatal injury.

To avoid serious or fatal injury, replace all Supplemental Restraint System (SRS) components only with parts specified in the Chrysler Mopar® Parts Catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection.

To avoid serious or fatal injury, the fasteners, screws, and bolts originally used for the Supplemental Restraint System (SRS) components must never be replaced with any substitutes. These fasteners have special coatings and are specifically designed for the SRS. Anytime a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the Chrysler Mopar® Parts Catalog.

To avoid serious or fatal injury when a steering column has an airbag unit attached, never place the column on the floor or any other surface with the steering wheel or airbag unit face down. Failure to follow these instructions may result in possible serious or fatal injury.

PLAN VIEW - TWO DOOR JK ONLY

Figure 1

SIDE VIEW - TWO DOOR JK ONLY

Figure 2

PLAN VIEW - FOUR DOOR JK ONLY

Figure 3

SIDE VIEW - FOUR DOOR JK ONLY

Figure 4

All welds should conform to the Chrysler LLC vehicle engineering process standard PS 9472.

Material Thickness

3.7 mm to 4.2 mm

3.7 mm to 4.2 mm

3.7 mm to 4.2 mm

Electrode Type

Lincoln Electrical Co. Product #: NR-211 MP

(Do Not Substitute)

AWS ER70S-6

(Do Not Substitute)

** AWS E 7018

Electrodes Size Inches

.045 Tubular

.035 Solid

3/32"

Electrode Stick Out

3/8" - 1/2"

1/2" - 5/8"

N/A

Polarity

Electrode "-"

Work Piece "+"

Electrode "+"

Work Piece "-"

Electrode "+"

Work Piece "-"

Shielding Gas

Self Shielded

75% Ar

25% CO2

Self Shielded

Gas Flow Rate

N/A

25 - 35 CFM

N/A

Wire Feed Speed

(inches per minute)

110 - 130 Vertical Down

70 - 90 Flat AND Overhead

245 - 250 Vertical Down

210 - 225 Flat AND Overhead

N/A

Approximate Amperage

Vertical

110 - 130

175

85 (3/32" Diameter)

Flat AND Overhead

70 - 90

155

90 (3/32" Diameter)

Voltage

15 - 18

19 - 20

N/A

Direction of Welding

Vertical

Vertical Down Hill (only)

Vertical Down Hill (only)

Vertical - Up Hill (only)

Flat AND Overhead

Flat - Push or Drag

Flat - Push or Drag

Flat - Drag