Frame Rust Problems of Dodge Magnum

My 2005 Dodge Magnum r/t burned through the unibody frame rails directly adjacent to the catalytic converters. This caused the frame to develop rust perforations. Damage is the same on both sides of the car, concentrated where the exhaust manifolds meet the catalytic converters. This is a difficult area to see, let alone inspect due to tight confines and heat from the exhaust system. It was found while changing the oil dipstick tube. The rest of the car is exceptionally clean and has never been undercoated, in an accident or winter driven. Numerous technicians looked at the problem at Chrysler and independent garages. All of them agreed the problem was caused by heat from the catalytic converters burning away the factory rust protection and then accelerating rusting of this structural area. The Chrysler dealer bodyshop quoted over $8000 to replace the rotted frame rails, mostly labor because they would have to remove the engine, transmission, exhaust, front subframe and much of the interior. The Chrysler dealer service manager sent in a report to his district service rep. I also filed a report with Chrysler customer care, case file number 25844173. They informed me that since the problem was not chronic with Magnums and the car was past its 3-year rust perforation warranty they would not repair the car or help with repair costs. This is a major structural defect with the frame of the car, not a mere rust hole in a body panel! I suspect the problem may be found in other Chrysler lx-body models of 2005 model year. Out of concern for the safety of these vehicles I walked around a local junkyard and found a 2005 model Chrysler 300 starting to show corrosion problems in the same frame areas adjacent to the catalytic converters. I have been documenting and photographing all of this.

See all problems of the 2005 Dodge Magnum 🔎.