Mopar STEALTH 1991 Repair Manual – Body Construction & Welding

If you’re trying to pull a Stealth unibody back to spec using a generic aftermarket guide, you’re flying blind. Factory body dimensions are not guesses — they’re the difference between a car that tracks straight and one that fights you at every bump. This Mopar STEALTH 1991 Repair Manual is the only set of instructions Chrysler released for the body shop. It’s 168 pages of weld schedules, panel replacement sequences, and corrosion sealing that the factory trained techs used. After spending 28 years in a shop, I’ve seen too many DIY guys buy a cheap aftermarket manual and end up with a car that pulls left because they didn’t have the right datum line. This manual is the actual factory document — not a reprint of a reprint. The Chrysler engineers who designed the Stealth wrote these pages. If you care about structural integrity, you use this.

Skip this manual and you’re guessing with sheet metal.

Mopar STEALTH 1991 Repair Manual: Body Construction Overview

The manual opens with the Body Construction chapter, covering the unibody structure. You get the exact locations of seam welds, spot weld pitches, and reinforcement layouts. If you’re replacing a rail or a quarter panel, this section tells you which joints to cut and which to leave. Page 1 shows the 1991 Stealth cover, but the real meat starts with the INDEX. Each subsection follows the factory assembly sequence, so you don’t weld yourself into a corner.

7 Sections in the Manual – What You Get

Here’s what’s inside:

• Safety Notice
• INDEX
• Body Construction
• Body Dimensions
• Welded Panel Replacement
• Corrosion Protection
• Synthetic-Resin Parts
• Body Color
• Reference Material
• Base Of Body Repair

The Safety Notice on page 2 warns about eye protection – consistent with Automotive Industry Overview standards. Read it before you touch a grinder.

Does This Manual Show You How to Weld?

Welded Panel Replacement is not a theory chapter. It gives specific welding methods to maintain original strength. Chrysler states that following these procedures keeps the vehicle’s durability. If you’re MIG welding on a Stealth, you need the joint design and heat settings from this manual. The section on spot weld removal and replacement alone is worth the download – it tells you how to avoid burning through the inner panel.

Get the Right Dimensions the First Time

Body Dimensions is the chapter that prevents a crooked car. Whether you’re measuring a strut tower or a firewall, the factory reference points are here. Aftermarket manuals often transpose metric to imperial wrong. This is OEM direct. You get the exact tolerances printed in inches – no conversion errors. Use these specs to set your frame rack or tram gauge before you commit to a pull.

Corrosion Protection: Factory Sealing Instructions

Corrosion Protection covers seam sealers, undercoating, and cavity wax. You don’t want to weld over untreated metal and invite rust. The manual tells you where to apply each material, including the specific areas around welded joints. The Synthetic-Resin Parts section also overlaps with trim repair – good to know if you’re dealing with bumper covers or interior panels.

Frequently Asked Questions

Do I need a body frame machine to use this manual?

Not always, but you need accurate measuring tools.

Can I use this manual for a 1992 Stealth?

The 1991 manual covers model year specific dimensions. While the chassis changed little, differences in corrosion protection and trim attachment exist. Using a 1992 manual is safer if that’s your year. However, this manual will give you the general unibody structure and welding procedures that carry over. Cross-check with a 1992 supplement if available. Without it, you risk mismatching body sealing or fastener locations. I would not use this for a different model year without verifying against the correct year’s data.

If you’re working on a 1991 Dodge Stealth (or its Mitsubishi cousin), this is the only body repair document that matches the factory build. Don’t rely on photocopied aftermarket versions. 1995-96 Import Parts Catalog: Vista, Summit, Stealth lists related models. For later Mopar parts, see 2007-2008 MOPAR Remanufactured Parts Catalog and 2006 MOPAR MAGNUM/300 LX Parts Catalog Accessories. For industry safety context, refer to Automotive Industry Overview. And if you need transmission specs, Manual Transmission is separate. Download the Factory Manual now.