Inside the Factory that Makes Jeep Wranglers

February 15th, 2019 by

When Fiat Chrysler Automobiles allowed cameras to see how Jeeps are assembled, we were able to see step by step how the beloved Jeeps are made, specifically the Wrangler. From how the employees divide their time right to the moment when the vehicle leaves the premises. Let’s take a look at how Jeeps are assembled from start to finish.

FCA builds its Jeep at their Toledo Assembly Complex in Ohio with over 5,600 employees who build 50 Jeeps an hour. They work on two shifts and they work on the Wrangler, the Wrangler Unlimited and the Grand Cherokee Jeep models.e. It all starts in the body shop.

The robots in the shop transfer the door of the Wrangler into the laser welder. In another part of the factory, multiple robot arms weld the door frame into place. The next step is the paint job.

The Jeeps go through several paint coats to assure the correct color. The paint shop robots also apply a clear coat to protect the paint. A buffer is used to wax the car and remove any imperfections after the paint dries.

The Wrangler then moves to the general assembly. This is where employees move the powertrain off of a carrier using a hydraulic arm. Back in the facility, an employee adheres the iconic Jeep badge and Wrangler decal to the body, that’s the stamps that you see on the side door of the Jeeps.

After the paint and decals are finished they work on the chassis (the underpart of a motor vehicle, on which the body is mounted– basically, the heart of the vehicle). That is placed on a carrier that rotates to provide access to the roof of the Wrangler. An employee then installs a header panel, the frame that the headlights and the grille mount to, while another employee secures the mirror mounting bracket.    

What comes next is the robotic arm that lifts the chassis and places it on a different part of the line. As the body moves down the line, another robot preps the front windshield with urethane. This will allow the windshield to bond to the chassis.

A robot then grabs the windshield and presses it to the chassis. Another employee carefully navigates the instrument panel around the frame and installs it at the front of the Wrangler. Further down the line, employees install the iconic seven-slot grille.       

Body and chassis decking is up next and at this station, the Wrangler body is married to the frame. At another part of the factory, an employee uses an ergonomic arm to transfer a hardtop roof for a Wrangler to a battery-powered, autonomous cart. With over 50 Jeeps built an hour, working seamlessly is needed.    

The automated guided vehicle (AGV) is what really does all of the heavy liftings. It can travel up to 150 feet per minute and they are accurate within a quarter of an inch of their target. This AGV will taxi the hardtop to the line, where another employee is waiting to seize the hardtop roof and drop it on the body.

It is almost at the finish line when an employee uses a hydraulic arm to gently position a door on the Wrangler. Wheels are then lifted onto studs on the wheel hub. A robot with a five-pronged wrench screw the lug nuts into place. The Jeep Wrangler is now fully assembled and goes off for a final wash. Finally, employees drive the finished Wrangler off the factory floor.  

This is how Jeeps, Wrangler, Wrangler Unlimited and Grand Cherokee are made from start to finish. Between employees and robots (and a lot of heavy liftings). To see how the Jeep is made, a brand that is still desirable all these years later can make for an interesting driving experience.     

If you’re interested in test-driving The Jeep Wrangler, Jeep Wrangler Unlimited or a Jeep Cherokee model, make sure to check them out at the Cape Coral Chrysler Dodge Jeep RAM dealership.

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