Dashboard / Instrument Panel: Service and Repair

Instrument Panel Carrier Replacement

Tools Required

J 1859-A Steering Wheel Puller

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.
2. Remove the instrument cluster bezel. Refer to Instrument Cluster Replacement Instrument Cluster Replacement.
3. Disconnect the electrical connectors.
4. Remove the three heater control screws. Pull the control rearward.
5. Disconnect the electrical connector from the back of the control assembly.
6. Remove the four radio control screws and the radio. Refer to Radio Replacement Service and Repair in Entertainment.
7. Remove the radio mounting bracket and the screw from the instrument panel.
8. Remove the instrument cluster. Refer to Instrument Cluster Replacement Instrument Cluster Replacement.
9. Remove the horn switch pad on the steering wheel. Refer to Horn Switch Replacement - On Vehicle Tilt in Steering Wheel and Column.
10. Disconnect the two horn electrical connectors in the center of the steering wheel. Refer to Horn Switch Replacement - On Vehicle Tilt in Steering Wheel and Column.
11. Remove the steering wheel. Refer to Steering Wheel Replacement Tilt in Steering Wheel and Column.




12. Remove the four steering column filler panel screws and the filler panel.
13. Remove the brake lamp switch from the brake pedal cross shaft.
14. Disconnect the hand throttle control cable at the throttle, if equipped.
15. Remove the two nuts holding the steering column support to the instrument panel reinforcement. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column.
16. Remove the three steering column to floor bolts. Lower the steering column and support. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column.
17. Remove the two speakers. Disconnect the electrical connectors from the speakers. Refer to Speaker Replacement (Front) Speaker Replacement (Front)Speaker Replacement (Rear) Speaker Replacement (Rear) in Entertainment.




18. Remove the center trim panel.

1. Open the instrument panel compartment door.
2. Pry out the door check straps at the instrument panel if equipped.

19. Remove the screw at the left side of the compartment door.
20. Remove the compartment door.
21. Remove the four screws retaining the compartment.
22. Remove the compartment.




23. Open the ash tray compartment. Remove the two top screws and the two bottom screws from the ash tray assembly.
24. Remove the ashtray light from the ashtray compartment.
25. Cut off the wiring harness retainer.
26. After lifting the assembly forward, disconnect the wiring from the lighter and the compartment lamp. Refer to Cigar Lighter Housing Replacement Service and Repair.
27. Remove the fuse block cover.
28. Remove the side trim panels from the hinge pillar cowl.




29. Remove the two mounting bracket to instrument panel screws.
30. Remove the five instrument panel upper mounting screws below the windshield.
31. Pull the top of the instrument panel back towards the seat. Roll the instrument panel on the mounting brackets.
32. For vehicles with air brakes, disconnect the air lines at the cowl.
33. Remove the following components from the back of the instrument panel:

* The defroster duct screws and the defroster duct
* The air conditioning duct screws and the duct
* The following have connectors holding the wiring harnesses to the instrument panel

- The hourmeter
- The screws holding the relay block
- The data link connector

34. Remove the instrument panel from the vehicle.
35. Transfer the following items to the new instrument panel:

1. The air valve mounting plate (air brakes)

* Remove the three screws at the bottom of the mounting plate bezel and the bezel.
* Remove the four screws holding the plate.
* Remove the mounting plate and the air brake lines.

2. The trim panel
3. The trim panel beneath the hourmeter and the throttle control
4. The hourmeter and the throttle control
5. The instrument cluster shroud screws and the shroud
6. The instrument panel compartment striker
7. The air conditioning duct at the right side of the instrument panel
8. All of the instrument panel mounting clips

Installation Procedure




1. Install the instrument panel to the mounting brackets.
2. Install the following items to the back of the instrument panel:

* The electrical harness
* The data link connector
* The relay block screws
* The hourmeter connector, if equipped
* The air conditioning duct and screws
* The defroster duct and screws

3. Connect the air lines to the cowl (air brakes).
Position the instrument panel back into place.





Important: Before installing the screws through the clips (1) at the cowl (3), center the slider (2) at the back of each clip on the clip.


4. Install the instrument panel and the five screws to the cowl.
5. Install the two mounting bracket to instrument panel screws.
6. Install the hinge pillar cowl side trim panels.




7. Install the ash tray assembly.

1. Connect the wiring for the cigar lighter and the lamp. Refer to Cigar Lighter Housing Replacement Service and Repair.
2. Install the ash tray assembly in the instrument panel and the screws.
3. Install the wiring harness retainer.
4. Install the ashtray light from the ashtray compartment.
5. Install the ash tray.




8. Install the instrument panel compartment and the four screws.
9. Install the compartment door and the screw.
10. Connect the door check straps to the instrument panel.
11. Install the center trim panel.
12. Install the two radio speakers. Connect the electrical connectors. Refer to Speaker Replacement (Front) Speaker Replacement (Front)Speaker Replacement (Rear) Speaker Replacement (Rear) in Entertainment.
13. Install the steering column and the support to the instrument panel reinforcement and the nuts. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column.
14. Install the three steering column to cowl bolts. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column.
15. Install the brake lamp switch to the brake pedal cross shaft.
16. Install the radio and the radio mounting bracket. Refer to Radio Replacement Service and Repair in Entertainment.




17. Install the steering column filler panel to the instrument panel.
18. Install the steering wheel with the nut and the retainer. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column.
19. Connect the horn switch electrical connectors to the horn pad. Refer to Horn Switch Replacement - On Vehicle Tilt in Steering Wheel and Column.
20. Install the horn pad to the steering wheel. Press the horn pad into place.
21. Connect the hand throttle cable at the throttle.
22. Install the instrument cluster and the screws. Refer to Instrument Cluster Replacement Instrument Cluster Replacement.
23. Install the control assembly and screws. Connect the wiring at the back of the control assembly.
24. Install the radio control assembly and the screws. Connect the wiring at the back of the radio control assembly.
25. Connect the headlamp switch and the electrical connectors.
26. Install the instrument cluster bezel and the screws. Refer to Instrument Cluster Replacement Instrument Cluster Replacement.
27. Install the fuse block cover.
28. Connect the negative battery cable.