Content provided in partnership with

Automotive Industry

Mid-size makeover: Dodge sets out to revitalize the mid-size pickup market with an updated version of the truck that started it all

Automotive Industries, Sept, 2004 by John Peter

In 1997 Dodge introduced a new Dakota mid-size pickup with styling that mimicked its successful full-size Ram big brother that debuted in 1994, using the Rams drop-fender, raised hood and semi truck-style large front grille. The following year, Dodge released the Durango, a mid-size SUV that was developed off of the Dakota platform sharing many parts with the Dakota, including the front sheet metal.

The process was reversed for this latest generation with the Durango taking the lead, growing in size to compete with SUVs like the Ford Explorer. When it came time to do the next generation Dakota, the logical step would have been to use the Durango platform.

Most Popular Articles in Autos: Service Slants; 2007 utility vehicle buyer's guide: Side-By-Sides are popular; here's who ...; Transmission considerations: beyond the manual gearbox; Buell Motorcycle engineering, innovation, & dedication: in an industry ...; 100 + 10: America's oldest automotive magazine celebrates its 110th year ...; More »

"We got the formula for the next generation Durango down and then went back and said, 'Now, let's do the same formula in reverse for the Dakota," says Program Manager, Steve Jakubiec. But Jakubiec says that the initial package drawings revealed a truck that was nearly the same size as the Ram. In a search for something that would fit the new platform, the team started to experiment with a Ford SportTrac type truck, based off of the SUV. "More of an SUT," says Jakubiec.

At a very strategic point in the program, several members of the marketing team pointed out that Dodge has a very loyal customer base for a Dakota-sized pickup. They argued that Dodge couldn't abandon those loyal customers--the division needed a mid-size truck Jakubiec says that was the changing point in the program and the SUT concept was scratched.

The new Dakota is based heavily on the old Dakota, not just sharing parts but most importantly sharing the build process with the current truck.

"We made zero carrier modifications within the assembly plant," Jakubiec says, "so we were able to run pilots right inside the assembly plant, more like the Japanese do."

All of the hard points were locked down before the first pilots were run, allowing for the pilot process to run very smoothly. All of the prototype bodies were built in the assembly plant, "Which is unheard of," says Jakubiec, and all of the pilot bodies were painted in the assembly plant.

A carry-over floor pan sits on an all-new frame with rails based on Ram 1500 technology. The fully-boxed frame marries hydroformed and stamped steel sections to create a frame that has eight-times greater torsional rigidity and two-times bending rigidity than the previous truck. The extra rigidity helps in both NVH and ride and handling. The straight center sections and some of the rear sections are hydroformed.

"If we had gone to all hydroforming," Jakubiec says, "we would have spent more money to strengthen areas that didn't need it."

The frame shares the octagonal front rail tips from the new Durango, adding to frontal crash performance. In fact, Dakota passes all 2008 NHTSA occupant restraint crash standards and 2006 50 mph rear offset crash standards.

"The only reason we did an all-new frame was to meet all the impact requirements," Jakubiec says, "or we would have gone off of the same platform."

Tower will again supply the frame for the new Dakota. The frame was quoted to another supplier, but due to Tower's proximity to the plant and the fact that the vehicle was basically the same, Tower was able to reutilize some of its current assets and come in with a lower bid.

The new Dakota features a re-designed coil-over front suspension that works for both two-wheel and four-wheel drive allowing Dodge to go to only one frame for the entire Dakota line-up.

"It's a little bit over-designed, heavier and more expensive for the 4x2 truck" says Jakubiec, "but it's still better from an overall synergy standpoint and less complexity in both our supplier and our assembly plant. If you think about it, the majority of our suspension variations are handled in the rear where all the payload variation is.

"What we're really trying to drive to as a company in the future is reduce flex in our plant," Jakubiec adds, "building more of the same so you can build it repeatedly, but give the customer something different."

The rear suspension is carried over but re-tuned to improve ride and handling. An all-new rack and pinion system targeted for a lighter more precise feel in handling.

The Dakota borrows an interesting manufacturing process from its Ram big brother. The front structure of the cab is made up of hydroformed tubes that the fenders bolt on to.

"The neat thing about it," says Jakubiec, "is that if you want to redo fenders, it's real easy because now it's just a stamping that's bolted on to the structure."

The hydroformed front end replaces the old Dakota's structural fenders, made up of an outer skin and a body-side aperture welded to the outer fender.

"We had a whole sub-assembly inside of our stamping plant that would take four to five pieces of sheet metal, weld them together dimensionally correct and hang them out there," Jakubiec says, "and it became very expensive to change."

Automotive Industry

Mid-size makeover: Dodge sets out to revitalize the mid-size pickup market with an updated version of the truck that started it all

Automotive Industries, Sept, 2004 by John Peter

Find Research Guides for:

Find Featured Titles for: Sports

Most Popular Articles in Autos

Most Popular Publications in Autos