Left side

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Marking Inner & Outer Rail - Left Side

Courtesy of CHRYSLER LLC

1 - MARK LOCATION 80 mm (3.2 in)

2 - CONTINUE MARK FROM INNER RAIL

3 - OUTER RAIL

4 - INNER RAIL

5 - REAR BATTERY TRAY WELD NUT

On inner rail (4), mark at 80 mm (3.2 in) (1) forward of centerline of rear battery tray weld-nut (located on top of rail).
On outer rail (3), continue mark (2) from inner rail (4).

Fig 2: Removing/Installing Bracket At Inner Rail
Courtesy of CHRYSLER LLC
Mark replacement part in same location.

On left rail (2), remove bracket (1) located on inner rail.

Fig 3: Identifying Cut Locations

Courtesy of CHRYSLER LLC

1 - CUT EXISTING PARTS ON FORWARD SIDE OF SCRIBED LINE

2 - LEFT SIDE

3 - RIGHT SIDE

Using a cut-off wheel, reciprocating saw or equivalent, cut all existing parts on the forward side of the scribe line (1) using care not to damage the material that will not be removed.
NOTE: Right rail section location: When installation of new tip is complete, there is a 6 mm (0.25 in) hole on the inner rail at the forward edge of the section joint which may need to be recreated or restored.

NOTE: Left rail section location: When installation of new tip is complete, there is a 10 mm (0.40 in) hole in bottom horizontal surface of rail which may need to be restored.
Cut all replacement parts on the rearward side of the scribe line again using care not to make any additional damage but do not discard any material yet.

Clean all sharp edges and create a slight taper for weld purposes.

Fig 4: Cutting Strips At Inner & Outer Rail

Courtesy of CHRYSLER LLC

1 - CUT OFF FLANGES

2 - CUT, REMOVE AND SAVE THESE PIECES (WELD BACKERS)

3 - CUT OFF FLANGES

4 - INNER RAIL

5 - CUT STRIP 19 mm (0.75 in)

6 - CUT STRIP 19 mm (0.75 in)

7 - OUTER RAIL

From the remaining replacement part, cut a 19 mm (0.75 in) strip (2) from both the inner and outer rail. Clip off the weld flanges (1 and 3), top and bottom, and dress edges. These pieces will be the weld-backer.

Prepare welding equipment per the weld chart. See Frame and Bumpers/Frame - Specifications .

Fig 5: Identifying Replacement Frame Rail Tip, Weld Backers, & Frame Rail

Courtesy of CHRYSLER LLC

1 - FRAME RAIL

2 - WELD BACKERS

3 - REPLACEMENT FRAME RAIL TIP

Install the weld-backers (2) into the frame rail (1), centering them on cut edge. Clamp and tack the weld-backers in position when proper fit is confirmed.
Dry fit the new rail tip (3) to verify alignment, fit and make any adjustments as necessary.
NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings.

CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
Using the appropriate measuring equipment, verify the front frame rail tip's location in all three (X, Y and Z) planes of space, and adjust if required. See Frame and Bumpers/Frame - Specifications .
Weld using a skip-stitch method until the full length of the joint is completed on both the inner and outer rail. To avoid excessive heat buildup, move between inner and outer rail during welding.
Dress welds without removing any base material paying particular attention to the mounting surface of the outer rail.

Install the bracket removed from the left rail.

Fig 6: Cleaning & Refinishing Repaired Areas

Courtesy of CHRYSLER LLC

1 - FESM STRUCTURE

2 - CLEAN AND REFINISH REPAIRED AREAS

3 - FESM STRUCTURE

4 - LEFT SIDE FRAME RAIL

5 - FRONT RAIL CAP PANEL

6 - RIGHT SIDE FRAME RAIL

7 - LOWER RADIATOR CROSSMEMBER

Either install new or reposition the lower radiator crossmember (7) and FESM structure (1 and 3) and clamp in place and weld.
Install new front rail cap panel (5).
Clean all repaired areas and apply appropriate refinish and corrosion protection materials.