The “No Compromises” SUV
The sport-utility vehicle segment has changed significantly since the original Dodge Durango launched in the fall of 1997. At that time, Durango was one of only a handful of legitimate SUVs that offered a combination of room, three rows of seating and big SUV capability. Durango occupied a unique market position with its “just right” size and real truck capability.

The 2004 Dodge Durango offers the perfect combination of interior space, refinement and a new trio of powertrains. With a standard V-6, available 4.7-liter V-8, and now the all-new 5.7-liter HEMI® Magnum V-8, Durango has a full-range of powertrains that deliver improved fuel efficiency across the board.

“The new Dodge Durango blends the attributes of both full-size and large SUVs. We revolutionized the SUV market with the original Durango and as the segment competitors have moved up in size to match us, we moved the new Durango up as well,” said Darryl Jackson, Vice President, Dodge Marketing. “The new Dodge Durango offers more of everything: more space, more power, more comfort, more capability. You can’t buy more SUV for your dollar. Period.

“The market is growing for sport utilities with three rows of seating, so Dodge worked to improve the overall packaging of Durango – and we delivered,” added Jackson.

The goals for the 2004 Dodge Durango were focused: improve the ride quality, refine the comfort and convenience level of the interior, utilize new technologies to improve safety, increase fuel efficiency and retain the capability that make it a Dodge.

To meet those targets, the 2004 Dodge Durango is larger than its predecessor – seven inches longer, three inches wider and more than three inches taller. With its third row seat folded and middle row up, the way the majority of three-row seat SUVs are driven, the 2004 Dodge Durango has more cargo room than Chevrolet Tahoe, Ford Expedition and Toyota Sequoia.

“Durango has increased head, hip and leg room, 102.4 cu.-ft. of cargo space and a Fold and Tumble™ third-row seat that provides seating for seven” added Jackson. “The Durango is designed for young active families who need their SUV for vacation, off-road, tow the boat or haul supplies for home improvement projects.”

New from the ground up, the 2004 Dodge Durango provides innovative tapered octagonal front frame rail tips and new advanced air bag protection. The vehicle is equipped with optional side-curtain air bags that cover all three rows of seating – one of the few sport utility vehicles on the market to offer this feature.

Improved ride and handling were two of the most prominent goals of the 2004 Dodge Durango. It features an all-new, and unique to Durango chassis. The result is an all-new Durango that offers a refined quiet ride with the handling edge nor normally associated with

Using the new, larger interior space and three-inch longer wheelbase to it’s full potential, Dodge has added more comfort and convenience features to the Durango. A new factory installed DVD system, with wireless headsets, can play MP3 and game systems. Durango also features an available 384 Watt stereo system with rear subwoofer and available Sirius® satellite radio.

Available on Limited models, a redesigned HVAC control panel features a new Automatic Temperature Control (ATC) climate control system that uses a dedicated microprocessor and an infrared sensor mounted in the overhead console to measure the temperature of the driver and the cabin. The all-new 2004 Durango is also available with a sunroof for the first time and a UConnect™ hands-free communications system with Bluetooth™ technology (late availability).

The rear doors on the 2004 Dodge Durango now open 84 degrees to provide easy ingress and egress, second row rear seats now offer an available recline feature and second row passengers also receive their own climate controls.

The all-new Dodge Durango has the interior room, towing and hauling capability of its large SUV competition, yet provides the fuel efficiency, performance and ride quality of the smaller full-size SUVs. The 2004 Dodge Durango will be available in three trim levels: ST, SLT and a new Limited package. SLT and Limited models feature available unique two-tone leather interiors.

Today, there are more than 67 SUV models.

Dodge Durango is no longer the new kid on the block. It has grown roots and has earned a reputation as a real SUV. The all new 2004 Durango offers more power, space and utility while maintaining its right-size position – a big SUV that’s not too big.

Customers expect all SUVs to offer superb comfort and convenience. With the all-new Durango, there is no need to let a desire for comfort get in the way of owning an SUV with some attitude.

Durango continues to offer real capability: utility to carry extra passengers, swallow bulky cargo, tow heavy loads and handle the most treacherous weather conditions.

Durango’s qualifications are anchored by the Hemi engine and substantial towing power, roominess, comfort and styling

“The spirit of the original Dodge Durango carries over to the all-new Durango,” said Darryl Jackson, Vice President – Dodge Marketing. “It exemplifies concepts like: ‘helps me live life to the fullest,’ ‘no limit to the possibilities,’ ‘delivers confidence whatever the situation’ and ‘whatever use that you need it for, it can deliver.’”

Compared to market segment competitors the Dodge Durango appeals to a wider range of prospects. It’s roomier and it can be equipped with a V-6 engine. Research indicates it will appeal to both families and empty nesters looking for a real SUV that allows them to do more, comfortably.

Dodge Durango’s primary target market is young active families with two to three children; relatively high $75,000 to $80,000 median household income; 50 to 55 percent female; about half are college graduates; 55 percent are white collar employees and seeking a vehicle that makes a statement about their active lifestyle and isn’t a “me too” SUV like the smaller SUV products.

Durango’s secondary target market is active, young-minded, older families with grown kids, recent empty nesters (48-55 years old) and people who enjoy outdoor activities like hunting, fishing, camping and boating.

Durango will attract full-size SUV intenders looking for more power and space, and large SUV intenders looking for real capability, but in a manageable package. Its differentiation from the pack – bold, stand-out styling and real truck capability bolstered by a 5.7-liter Hemi engine – plays a crucial role in forging its position in the marketplace.

Dodge’s new Durango will offer all the power, capability and style buyers expect from Dodge, all the comfort and convenience they need in a modern SUV.

“With the all-new Dodge Durango, there is no need to let your desire for comfort get in the way of owning an SUV with some attitude,” added Jackson.

The Dodge Durango is unique – the intersection of luxury, performance technology and style.

(Published November 1, 2003) ©1998-2003 DaimlerChrysler. All rights reserved.
BOLDNESS OF DESIGN ELEVATES THE SUV PLATFORM

Breaking away from a conformist crowd, the all-new 2004 Dodge Durango elevates the form of the SUV from utilitarian tool to machined elegance. Its unmistakable Dodge DNA courses through its design, from its bold cross-hair grille to the HEMI rumble from the exhaust.

“With its steeply raked windshield and powerful grille design, the Dodge Durango is not a ‘me too’ design,” said Trevor Creed, Senior Vice President, Design. “Our goal was to create something more architectural; a vehicle that still delivers power on every front, from its dramatic Dodge grille and powerful stance to its towing and cargo hauling capability.”

The 2004 Dodge Durango has a muscular definition and taut lines without the boxiness normally associated with SUV designs. The silhouette is unique among SUVs, with short front and rear overhangs, prominent wheel arches and a dramatically sloping windshield for improved aerodynamics and fuel efficiency.

“The Durango channels the design DNA of the original 1946 Dodge Power Wagon through its drop fender design and powerful grille. It blends these design elements with the Power Wagon Concept and the crisp profile of the Power Box Concept to deliver a modern execution of a Dodge SUV,” said Rick Aneiros, Vice President, Truck Design. “The powerful design recalls our Dodge heritage and delivers a sense of strength, but with a crisp, sculpted look. The boldness of the new Durango design could only come from Dodge.”

The grille conveys a powerful and prominent Dodge signature, with the large cross-hair as the focal point. The flared wheel arches transition the power from the grille to the rear of the vehicle and the roofline dips slightly at the rear to distinguish the silhouette.

Styling details abound, with single headlamp covers hiding dual lights that add a contemporary look and flow into the strong shoulder designs. The side-view mirrors were crafted in the wind tunnel to reduce noise from wind turbulence. The overall rear design of the Durango is clean, functional and features “afterburner” taillamps. The center high-mounted stop lamp is integrated smoothly into the rear roofline. Even the rear window wiper was designed with an angular, molded shape.

Style, Comfort and Capability
The design philosophy behind the interior of the 2004 Dodge Durango is a surface structure that suggests pure geometry. Surface sections are made up of more constant radii, delivering a cleaner and simpler overall form resulting in a functional and elegant inside appearance.

“An SUV has certain interior requirements, with space, storage and driving position being paramount,” said Creed. “The goal was to create this with a clean, precise interior design that is both simple and elegant through the use of refined materials and crisp lines.

The new instrument panel cluster features a large, centrally located speedometer and white-faced gauges that provide a connection to other Dodge performance vehicles. Available on Limited models, a redesigned HVAC control panel features the new Automatic Temperature Control (ATC) climate control system.

The ATC unit uses a dedicated microprocessor and an infrared sensor mounted in the overhead console to measure the temperature of the driver and the cabin. The new system measures ambient temperature and the engine cooling system, delaying the flow of air in cold conditions until warm air is available. The unit also has controls for the rear air conditioning system.
A redesigned manual control unit is standard.

The steering wheel features a new four-spoke design and the vertical edges of the dash drop down to the center stack to divide the driver and passenger seating areas. “Venetian Blind” style air vents close flush and provide a cleaner appearance.

Designed for ease of use, the center console features a large storage bin created to hold bulky items and the integrated cup holders are lined with neoprene rubber to provide a better fit for a variety of drink containers.

The Perfect Balance for Passengers and Cargo
The all-new 2004 Dodge Durango packages the type of generous interior space and abundant storage usually found on larger SUVs. Three inches were added to the Durango’s wheelbase to offer increased interior cargo volume in an SUV package that offers better handling than the large SUVs.

Easy ingress and egress to the second and third row seating positions are improved on the new Dodge Durango with rear doors that open 84 degrees. With an available innovative split folding third row seat design, Durango improves flexibility without losing capability.

Second row rear seat passengers now get their own climate controls and a DVD entertainment system that includes wireless headsets and integrated game ports. The second and third row rear seats feature more leg, shoulder and hip room than the current-generation Durango. The second row seats also have a new recline feature. The all-new 2004 Durango is also available with a sunroof for the first time.

A new nine-speaker, 384-Watt Infinity® sound system with Ceramic Metal Matrix speakers and a subwoofer deliver booming sound for CDs and DVDs is optional, as is Sirius Satellite Digital Radio.

Also for 2004, UConnect™ hands-free communications system with Bluetooth™ technology is available (late availability). The system can recognize up to seven different Bluetooth-equipped cellular phones and responds to voice commands, utilizing a microphone in the rear-view mirror and the stereo system’s speakers for hands-free conversations.

Superior Cargo Capacity
The 2004 Dodge Durango delivers 68.4 cu.-ft. of cargo room with the third-row seats folded. Durango easily surpasses full-size SUVs, with more than a 20 cu.-ft. advantage over Ford Explorer and also beats Chevrolet Tahoe and Ford Expedition.

MORE POWERFUL AND EFFICIENT: DURANGO EXPANDS ENGINE LINE UP WITH FIRST EVER V-6 POWER AND HEMI® MAGNUM V-8

For 2004, Dodge Durango leaves the competition standing still with the injection of some serious new muscle. With a standard 210 horsepower 3.7-liter Magnum V-6 and the award-winning 5.7-liter HEMI® Magnum V-8 offered as option, Durango has all the bases covered. The 4.7-liter Magnum V-8 returns to round out an impressive powertrain lineup that delivers improved fuel efficiency across the board. The 5.7-liter HEMI Magnum offers a full 90 horsepower improvement over the 5.9-liter Magnum that it replaces.

“The new Magnum V-6 powertrain allows Durango to compete directly against full-size SUVs on price and fuel efficiency,” said Frank Klegon, Vice President, Truck Product Team. “And with the addition of the all-new HEMI Magnum V-8, which debuted on the tough Dodge Ram 1500, 2500 and 3500 pickups, this all-new SUV has a lineup of engines that is hard to match for versatility, power and capability.”

More Powerful and Efficient
First offered on the 2003 Ram Heavy Duty, the new 5.7-liter HEMI Magnum V-8 delivers a 10-percent improvement in fuel efficiency versus the previous generation 5.9-liter V-8. With 335 horsepower @ 5,400 rpm and 370 lb.-ft. @ 4,400 rpm, the new HEMI Magnum delivers a 40-percent improvement in horsepower and a 12-percent improvement in torque versus its predecessor. Equipped with HEMI, Durango sets acceleration and towing class records.

The 2004 Durango is also available with the 230 horsepower @ 4,600 rpm 4.7-liter Magnum V-8 engine. With 290 lb.-ft. of torque @ 3,600 rpm, the 4.7-liter provides smooth and responsive performance and is mated to the 5-45RFE automatic transmission, the only transmission in its class with the reverse gear ratio equal to the low gear ratio. The 5-45RFE also features a unique alternate second gear ratio for use in difficult towing and grade-climbing situations.

Automatic transmission-equipped Durangos with either the 4.7-liter Magnum or the 5.7-liter HEMI Magnum offer a “Tow/Haul” transmission feature that provides crisper shifts and reduces gear searching when towing by holding the lower gear longer. The system will also select a lower gear under downhill conditions to capitilize on the engine’s braking capability.

New to the Dodge Durango lineup is the 3.7-liter Magnum V-6, standard on two-wheel drive Durangos delivering 210 horsepower at 5,200 rpm and 235 lb.-ft. of torque at 4,000 rpm. The 3.7-liter provides improved fuel efficiency and replaces the 4.7-liter as the base engine on Durango.

Built From the Ground Up as an SUV
Improved ride refinement and handling were two of the most prominent goals of the 2004 Dodge Durango redesign. To that end, the Dodge Durango features an all-new, and unique to Durango, chassis. The result? The all-new Dodge Durango features a refined and quiet ride but with a handling edge not normally associated with large sport utility vehicles.

All-new Frame
The all-new, torsionally stiffer, hydroformed and fully-boxed frame is linked to an independent front suspension with rack and pinion steering. Despite the addition of three inches to new Dodge Durango’s wheelbase, improved front suspension packaging allowed engineers to decrease the Durango’s turning radius to 37.5 ft., better than a Honda Pilot.

“The Dodge Durango is all-new from the ground up with a hydroformed and fully boxed frame and chassis that are unique to Durango,” said Klegon. “The ride and handling bar has been raised in the SUV segment, so we custom designed this chassis to be a refined SUV from the start. We were able to take many of the lessons learned on the design and construction of our new Dodge Ram pickup frames in the areas of hydroforming and suspension tuning, but with an SUV as our goal. What we have delivered is an exceptional handling SUV that literally leaves the ever-crowded look-alike SUV pack in our dust.”

The new hydroformed Durango frame was designed to improve not only handling and accident avoidance, but excellent crash protection as well. New, patented octagonal front frame rail tips are designed to absorb frontal impacts more consistently and can be removed to ease repair without frame replacement.

Tough Design Improves Crash Protection
Dodge engineers also moved the steering rack behind the front suspension, reducing the transference of energy to the driver in an accident. The bumper height of the new 2004 Dodge Durango is within the bumper height zone of passenger cars and engages the structures of vehicles in the event of an impact. The 2004 Dodge Durango was also designed to meet future government crash tests and passes 50 mph offset rear impact tests that measure fuel system integrity.

The extensive use of hydroformed parts also simplifies the frame manufacturing process and reduces the overall number of welds, contributing to improvements in dimensional integrity and durability by limiting variations in the manufacturing process. Thanks to the consistency of the new frame dynamics, the suspension and steering can be finely tuned to deliver superior ride and improved steering feel. A new traction control system and available full-time four-wheel drive improve Durango’s on-and off-road capability.

New Rear Suspension/Real SUV Capability
Greatly improving the ride of the Durango is an all-new rear suspension with link coil design and a solid rear axle that provides a smooth ride, improves durability and delivers improved payload and a best-in-class towing capability.

“We examined independent rear suspension designs, but found that we could save weight with our design and still achieve our ride targets with a link coil set up,” Klegon said. “The solid axle system also allows us to provide a greater tow capacity. But more important than how much we can tow is the way the Durango goes about towing. Our rear-wheel geometry is markedly better under load than with an IRS system, and that translates to a more settled trailer and smoother handling while towing.”

A unique Watt linkage system is fitted to the rear axle, centering the axle and reducing rear-end stability over rough surfaces. This design also enabled the lowering of the cargo floor, aiding cargo capacity. The result: a Gross Vehicle Weight Rating (GVWR) of 6,600 lbs. and the ability to tow 8,950 lbs.

“SUVs were built with a purpose in mind, and the Dodge Durango delivers the utility that our customers want,” added Klegon. “The Watt linkage design not only helps to improve the new Durango’s ride, but it also allowed us to lower and widen the rear cargo floor, enabling Durango to carry a 48-inch sheet of plywood – an industry benchmark. The Durango gets the job done, no excuses.”

Quiet and Refined
The 2004 Dodge Durango was designed to be smoother and quieter than its predecessor and noise vibration and harshness were attacked at every opportunity.

“The new frame is stiffer and more tunable to eliminate NVH issues,” said Klegon. “To alleviate noise transmission to the passenger compartment, expandable polyurethane foam is injected into the body cavities. This prevents the frame from acting as a conduit for road and wind noise. We also increased the amount of door, glass and body sealing and lowered body air leakage by more than 35 percent. This all adds up to a very quiet and refined interior.”

Further aiding noise reduction, front door glass is 20 percent thicker than the previous generation Durango and rubber mounts for front and rear wiper systems have been installed to reduce noise. A rubber isolated rack and pinion steering gear and uniquely calibrated engine mounts were also designed to eliminate the unique frequencies and harmonics of each power unit.

New Braking System
The 2004 Dodge Durango features the braking system fitted to the Dodge Ram 1500 pickup, with standard four-wheel disc brakes, ABS and 17-inch wheels. At 13.2 inches front and 13.9 inches rear, Dodge Durango’s brake rotors provide the Durango with excellent stopping and accident avoidance capability, decreasing 60-0 mph braking distances by 10 percent. In fact, the new system performs even better under load, improving stopping distances by 13 percent at GVW (gross vehicle weight).

Durango also features a twin-stage booster and a new Electronic Brake Force Distribution (EBD) system that balances front to rear braking effort under normal conditions. It adjusts hydraulic pressure to the rear brakes based on the amount of tire slip indicated by the ABS wheel speed sensors and automatically adapts to variations in vehicle loading and road surface.

The new ABS system also includes a unique off-road logic program when the transfer case is in 4LOCK or 4LO mode, adjusting its response characteristics for slippery or deformable surfaces to optimize stopping distance.

All-New Traction Control
The 2004 Dodge Durango offers an optional and all-new traction control system on all models. The low-speed system monitors wheel slip at each wheel and modulates brake pressure to regain traction. The system transfers torque to the wheel with traction and can be deactivated.

Designed for both on and off-road surfaces, the traction control applies greater brake pressure modulation when the transfer case is in either 4LOCK or 4LO. Using the pressure modulation capability of the ABS system, the traction control system provides torque to the wheel with traction.

2004 Dodge Durango, A Driving Force that Begins with Safety

2004 Dodge Durango SLT Interior

2004 DODGE DURANGO, A DRIVING FORCE THAT BEGINS WITH SAFETY

Chrysler Group engineers set high standards for the 2004 Dodge Durango’s safety with a comprehensive approach to safety that includes lowering the height of the front frame and bumper for passenger car compatibility. By verifying the protective features through severe crash tests that exceed current government and industry requirements, engineers were able to achieve a robust frame for optimal occupant security.

New from the ground up, the 2004 Dodge Durango provides innovative tapered octagonal front frame rail tips and new advanced air bag protection. The vehicle is equipped with optional side-curtain air bags that cover all three rows of seating – one of the few sport utility vehicles on the market to offer this feature.

“The Chrysler Group developed and designed the 2004 Dodge Durango with a holistic approach to safety that included stringent safety targets from the beginning,” said Frank Klegon, Vice President, Truck Product Team. “We fused the best performance characteristics and innovative safety features into one impressive vehicle package to create the all-new Dodge Durango.”

Valuable Crash Protection Benefits
Crush initiators, located on the front-end of the vehicle, activate the Durango’s new, patented octagonal front frame rail tips during an accident. The rail tips fold up like an accordion during a crash to absorb as much energy as possible in order to reduce crash forces for vehicle occupants. The Durango’s lower bumper and frame were designed to be within the height and level as passenger car bumper zones.

Chrysler Group was one of the first companies to introduce side-curtain air bag technology to cover all-three rows with the 2004 Chrysler Pacifica. That innovation continues with the Dodge Durango, one the first SUVs available with this safety feature.

The Durango also is one of the first Chrysler Group vehicles to offer an advanced air bag with an occupant classification system for the front occupants. This new system determines the conditions for air bag deployment based on occupant weight. This advanced system is designed to meet government requirements. Regardless of the type of air bag, the safest place in any vehicle for children 12 years old and under is in the back seat.

The first line of defense in an impact are the seat belts. Durango’s front seats are equipped with constant force retractors and seat belt pretensioners. Pretensioners tighten the seat belt to keep the occupant in place while constant force retractors balance the load on the upper body reducing injuries from excessive seat belt forces. Three point seat belts and head restraints are installed in every seating position including the second and third row center occupants. The driver’s side is also equipped with BeltAlert – a new enhanced seat belt reminder system that periodically activates a chime and illuminates a light in the instrument cluster to remind the driver to buckle up.

“Collectively, Dodge Durango’s structure, features and extensive testing help provide a cocoon of protection to absorb energy and deflect it away from passengers in a crash,” said Mike Cairns, Senior Manager, Vehicle Development. “For instance, the energy absorbing steering column is designed to take energy away from the driver’s chest in the event of a crash.”

Safety engineers evaluated the Dodge Durango with tests beyond current government requirements such as 40 mph front offset and 50 mph rear impact-tests. The 40 mph front impact simulates a high speed vehicle-to-vehicle crash while the 50 mph offset rear-impact test measures fuel system integrity when the vehicle is hit at high speeds on the side nearest the fuel tank.

Handling and Stability Refinements
During its development, the Dodge Durango was evaluated in a wide range of tests to maximize control in hazardous and challenging conditions and to provide excellent handling and stability capabilities

2004 Dodge Durango Safety and Security Features

Advanced Multistage Air Bag System: Provides enhanced protection for a wider range of occupants at various levels based on the severity of the crash.

Anti-lock Braking System: Standard ABS provides the Dodge Durango with unparalleled braking and accident avoidance capability with the ability to decrease 60-0 mph braking distances by 15 feet over the previous generation Durango.

Body Structure: Crush beads and stiffeners engineered into the vehicle body help absorb energy, while preserving the integrity of the vehicle compartment. These reinforcements provide additional protection in an offset-type impact.

Child Seat Anchor System (LATCH): Lower Anchors and Tethers for CHildren eases installation of compatible aftermarket child seats.

Constant Force Retractors (CFR): The front seat belts include a mechanical device designed to distribute the force of a seat belt according to the load or force exerted on it. CFRs are engineered to force-limit the belt system, and gradually release seat belt webbing in a controlled manner during a severe crash.

Electronic Brake Force Distribution (EBD): This new system balances front-to-rear braking. The hydraulic pressure is adjusted to the rear brakes based on the degree of tire slip indicated by the ABS wheel speed sensors and adapts to variations in vehicle loading and road surface.

Enhanced Accident Response System: In the event of an accident, this system makes it easier for emergency personnel to see and reach the occupants by turning on the interior lighting and unlocking the doors after air bag deployment.

Energy-Absorbing Steering Column: The collapsible steering column absorbs more energy, potentially reducing chest injuries in a collision.

Front Crush Sensors: Two sensors, located inside the engine compartment below the headlamps, measure the severity of the impact and relay crash information to safety systems in the occupant compartment.

Occupant Classification System (OCS): The OCS measures conditions for activiation or deactivation of the passenger side air bag based upon the weight of the occupant.

Octagonal Front Frame Rails: The front rail tips feature a unique design and shape and fold up like an accordion in the event of a crash, absorbing frontal impacts more consistently than other frame rail designs.

Pretensioners: During a collision, the front seat belt pretensioners electronically sense a severe crash and immediately remove slack from the seat belts thereby reducing the forward movement of the occupant’s upper body.

Side Curtain Air Bags: The side curtain extends protection to outboard passengers in all-three rows of seating.

Steering Rack: The steering rack, now located behind the front suspension, allows more crush space within a shorter front end length.

Three-point Lap/Shoulder Belt: All seven seating positions feature a three-point restraint system, which maximizes the effectiveness of the seat belt.

Traction Control System: All-new optional, low-speed traction system monitors wheel slip at each wheel and modulates brake pressure to regain traction. The system transfers torque to the wheel with traction and can be deactivated.

Chrysler Group President Dieter Zetsche Launches Production of All-New 2004 Dodge Durango at Newark Assembly Plant

Chrysler Group President Dieter Zetsche Launches Production of All-New 2004 Dodge Durango at Newark Assembly Plant

• New Dodge Durango production marks the kickoff of 10 new products for Chrysler Group by the end of 2004
• $180 million investment in Newark Assembly adds flexibility to operations
• Quality verified over 125 times per vehicle before leaving the plant

Chrysler Group President and CEO Dieter Zetsche joined more than 2,000 employees at the Newark (Del.) Assembly Plant today to launch the official production of the all-new, larger 2004 Dodge Durango. The event signaled the advent of an unprecedented string of new product launches for the Chrysler Group.

“Today marks the beginning of 10 new product launches for Chrysler, Jeep® and Dodge by the end of 2004 and our manufacturing operations play a critical role in the successful introduction of these vehicles,” said Zetsche. “The same rigorous efforts at Newark Assembly that have improved quality and flexibility will be incorporated into our other plants as we ramp up for new vehicle production.”

The All-New 2004 Dodge Durango
At approximately seven inches longer, three inches taller and three inches wider than the previous Durango, the 2004 Dodge Durango is a large SUV with the drivability, fuel efficiency and price of a full-size competitor.

For 2004, the Dodge Durango starts with an all-new, stand-alone platform and an all-new hydro-formed and fully boxed frame for added stiffness and refinement. With a three-inch-longer wheelbase and a new coil spring rear suspension with a Watt-link design, Durango out-handles the competition, while delivering a smooth, refined ride.

Dodge Durango matches or betters the large SUV competition in towing capability and interior space. It has a towing capacity of 8,950 pounds and features a 15 percent increase in cargo volume with 102.4 cubic feet of cargo space. With its third-row seat folded, Durango beats out other large SUVs, including the Chevrolet Tahoe, Ford Expedition and Toyota Sequoia.

The vehicle features a new trio of engines that deliver a 10 percent improvement in fuel efficiency. They include the 5.7-liter HEMI® Magnum engine, delivering a best-in-class horsepower and torque rating, as well as the 4.7-liter Magnum V-8 and the 3.7-liter Magnum V-6.

The all-new 2004 Dodge Durango will be available in dealerships across the country beginning November 15. Details related to Durango pricing will be announced prior to the dealer launch. The new model's residual value will be above the one it replaces.

$180 Million Invested
The Chrysler Group invested approximately $180 million in the Newark Assembly Plant in preparation for production of the all-new Durango. Through flexible manufacturing strategies and reusing existing plant equipment, the company has been able to reduce initial capital expenditures by 30 percent.

“The all-new Dodge Durango will offer more vehicle options than its predecessor, and will be produced more efficiently, requiring fewer production hours per vehicle,” said Tom LaSorda, Chrysler Group Executive Vice President, Manufacturing. “We are demonstrating through the launch of this vehicle that flexibility can be applied to an existing, and quite mature, manufacturing operation.”

The approach at Newark Assembly underscores Chrysler Group’s ongoing commitment to further improve productivity and flexibility in its manufacturing operations, both of which have a direct impact on vehicle quality.

Engineering, Procurement and Supply and Manufacturing Collaboration
From the outset, Chrysler Group’s Engineering, Procurement and Supply and Manufacturing organizations worked together to develop the all-new Dodge Durango, ensuring the highest levels possible for quality, safety and manufacturing flexibility. This concept, commonly known as “design for manufacturing,” involved a comprehensive review of the previous Durango development and production processes.

“Designers and engineers were joined in a common effort – to produce a vehicle that meets the customers’ highest quality standards the first time it rolls off the line,” said Zetsche.

Further, plant employees were engaged early in the development process. Their input prompted engineers to reconsider aspects of the vehicle’s design and assembly process. It also led to the introduction of new ergonomic approaches, thereby creating a safer work environment for employees.

This broad approach to vehicle development also involved various partners, ranging from plant tooling and equipment producers to vehicle parts suppliers. As a result, the assembly process has been streamlined, despite the addition of more options on the vehicle.

Quality Verified 125 Times per Vehicle
Newark Assembly also instituted an extensive quality program that integrates over 125 unique quality checks throughout the production process, from the body shop to final assembly and pre-shipment to dealers. The basis for the program was customer feedback and assembly benchmarking both within and outside the company.

The new quality verification processes enable employees at all levels to identify and resolve quality issues during production. It is expected that these actions will help lower future warranty costs.

From Tanks to Robots
The Newark facility was originally built in 1950 to assemble tanks for the military. At that time, it was considered a state-of-the-art complex. Today, the plant takes the assembly process to new levels through the use of robotics and other forms of technology.

The facility underwent a conversion to re-tool existing equipment and processes, enabling both the new Dodge Durango and its predecessor to be built simultaneously on the same production lines. The plant also minimized the amount of time required to change over plant equipment from the previous production model to the one that is being launched today.

Nearly 300 robots were put in place for production of the all-new Durango, most of them installed in the new body shop. The body shop was created in pre-existing, unused space at the plant. Also, tooling from the old shop was utilized, thus furthering cost efficiency.

Within the paint shop, two new processes and technology have been added to the line to give Durango a smooth, quiet ride in all types of road conditions: PUR foam application and Liquid Applied Sound Deadener system (LASD). PUR foam is a patented noise suppression adhesive that is injected into the body of the vehicle to minimize noise, vibration and harshness (NVH).

The second technology, LASD, is an underbody system that applies a liquid compound to the vehicle’s floor pan. This sound deadening fluid is applied in a highly precise motion by robots and helps reduce noise inside the vehicle.

Newark Assembly is one of the few automotive paint shops in the world that utilizes a patented “Super Solids” clear coat technology for improved scratch and mar resistance, while reducing paint emissions by 25 percent.

The all-new 2004 Dodge Durango will be available for sale this November.
 

Published November, 2003) ©1998-2003 DaimlerChrysler. All rights reserved.