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Home >> Dodge and Ram >> 2002 >> RAM 2500 Truck 4WD V10-8.0L VIN W >> Repair and Diagnosis >> Instrument Panel, Gauges and Warning Indicators >> Instrument Cluster / Carrier >> Service and Repair >> Procedures >> Instrument Cluster Disassembly and Assembly

Instrument Cluster Disassembly and Assembly



DISASSEMBLY
Some of the components for the instrument cluster used in this vehicle are serviced individually. The serviced components include: the automatic transmission gear selector indicator, the incandescent instrument cluster indicator lamp and illumination lamp bulbs (including the integral bulb holders), the cluster lens and hood unit, and the cluster housing rear cover. The remaining components are serviced only as a part of the cluster housing unit, which includes: the cluster housing, the electronic circuit board unit, the cluster overlay, the gauges, and the odometer/trip odometer reset switch button. Following are the procedures for disassembling the serviced components from the instrument cluster unit.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

Gear Selector Indicator
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. Instrument Cluster Replacement
3. Remove the steering column opening cover from the instrument panel. [1][2]Service and Repair

Fig. 4 Gear Selector Indicator Cable Remove/Install:





4. Reach through the instrument panel steering column opening to access and disengage the loop end of the gear selector indicator cable from the PRNDL driver lever on the left side of the steering column (Fig. 4).
5. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window.
6. Remove the gear selector indicator mechanism and cable unit through the instrument panel cluster opening.


Cluster Bulb
This procedure applies to each of the incandescent cluster illumination lamp or indicator lamp bulb and bulb holder units. However, the illumination lamps and the indicator lamps use different bulb and bulb holder unit sizes. They must never be interchanged.
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. Instrument Cluster Replacement

Fig. 5 Cluster Bulb Remove/Install:





3. Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board (Fig. 5).
4. Pull the bulb and bulb holder unit straight back to remove it from the bulb mounting hole in the cluster electronic circuit board.


Cluster Lens And Hood
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. Instrument Cluster Replacement

Fig. 6 Instrument Cluster Components:





3. Remove the seven screws that secure the lens and hood unit to the cluster housing (Fig. 6).
4. Gently pull the lens and hood unit away from the cluster housing.

CAUTION: Do not touch the face of the gauge overlay or the back of the cluster lens with your finger. It will leave a permanent finger print.

Cluster Housing Rear Cover
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. Instrument Cluster Replacement


Fig. 7 Cluster Housing Rear Cover Remove/Install:




3. Remove the six screws that secure the rear cover to the back of the cluster housing (Fig. 7).
4. Remove the rear cover from the back of the cluster housing.

Cluster Housing
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. Instrument Cluster Replacement
3. Remove the lens and hood unit from the cluster housing.
4. Remove the rear cover from the cluster housing.


ASSEMBLY

Gear Selector Indicator
1. Position the gear selector indicator mechanism and cable unit into the instrument panel cluster opening.
2. Route the cable through the instrument panel and under the steering column to the PRNDL driver lever on the left side of the steering column.
3. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window.
4. Engage the loop end of the gear selector indicator cable onto the PRNDL driver lever on the left side of the steering column (Fig. 4).
5. Reinstall the instrument cluster onto the instrument panel. Instrument Cluster Replacement
6. Confirm proper operation of the gear selector indicator. Calibrate the indicator, if required.
7. Reinstall the steering column opening cover onto the instrument panel. [1][2]Service and Repair
8. Reconnect the battery negative cable.


Cluster Bulb
This procedure applies to each of the incandescent cluster illumination lamp or indicator lamp bulb and bulb holder units. However, the illumination lamps and the indicator lamps use different bulb and bulb holder unit sizes. They must never be interchanged.

CAUTION: Be certain that any bulb and bulb holder unit removed from the cluster electronic circuit board is reinstalled in the correct position. Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the instrument cluster, the electronic circuit board and/or the gauges.

1. Insert the bulb and bulb holder unit straight into the correct bulb mounting hole in the cluster electronic circuit board (Fig. 5).
2. With the bulb holder fully seated against the cluster electronic circuit board, turn the bulb holder clockwise about sixty degrees to lock it into place.
3. Reinstall the instrument cluster onto the instrument panel. Instrument Cluster Replacement
4. Reconnect the battery negative cable.

Cluster Lens And Hood

CAUTION: Do not touch the face of the gauge overlay or the back of the cluster lens with your finger. It will leave a permanent finger print.

1. Align the cluster lens and hood unit with the cluster housing. Be certain that the odometer/trip odometer switch button is installed through the clearance hole in the lens (Fig. 6).
2. Install and tighten the seven screws that secure the lens and hood unit to the cluster housing. Tighten the screws to 2.2 Nm (20 in. lbs.).
3. Reinstall the instrument cluster onto the instrument panel. Instrument Cluster Replacement
4. Reconnect the battery negative cable.

Cluster Housing Rear Cover
1. Position the rear cover onto the back of the cluster housing (Fig. 7).
2. Install and tighten the six screws that secure the rear cover to the back of the cluster housing. Tighten the screws to 2.2 Nm (20 in. lbs.).
3. Reinstall the instrument cluster onto the instrument panel. Instrument Cluster Replacement
4. Reconnect the battery negative cable.

Cluster Housing
1. Assemble the rear cover onto the cluster housing.
2. Assemble the lens and hood unit onto the cluster housing.
3. Reinstall the instrument cluster onto the instrument panel. Instrument Cluster Replacement
4. Reconnect the battery negative cable.
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