DODGE TRUCK 1993 Service Repair Manual

8E
- 10
INSTRUMENT
PANEL
AND
GAUGES

GROUND
OIL
PRESSURE

SENSOR
INPUT

J908E-70

Fig.
10 Oil Pressure
Sending
Unit—Gas Engine

STEERING
PUMP
ENGINE
BLOCK

J9119-74

Fig.
11 Oil Pressure
Sending
Unit—Diesel Engine
SENDING
UNIT
(GAUGE)

SWITCH
(LIGHT)
898E-2

Fig.
12 Combination Oil Unit Terminals

VOLTAGE
GAUGE
CIRCUIT
TEST
(1) Remove voltage gauge. Refer to Gauge Replace­
ment.
Fig.
13 Oil Pressure
Gauge
Pins

r— FUEL
PUMP
SUPPLY

0 INPUT TO
GAUGE
-SENDING
UNIT
GROUND

-FUEL
PUMP
GROUND
J928E-49

Fig.
14 Fuel Tank
Sending
Connector Terminals

FUEL
GAUGE
INPUT

^
GROUND
y
J908E-71

Fig.
15 Fuel
Gauge
Pins

(2) With the ignition switch in the ON position,
check for battery voltage across the B+ pin and the Ground pin (Fig. 16).
The instrument panel voltmeter indicates elec­
trical system battery voltage.

SPEEDOMETER
(1) Remove speedometer assembly. Refer to Gauge
Replacement.

•

Fig.
16
Voltmeter
Pins

(2) Check for continuity in the wire between the
distance sensor connector and the speedometer (dis­
tance sensor input pin) (Fig. 17).
(3) With the ignition switch in the ON position,
check for battery voltage across the B + pin and the Ground pin. —
INSTRUMENT PANEL
AND
GAUGES
8E - 11

Fig.
17 Speedometer
Pins
(4) Perform distance sensor test. Refer to General
Information - Distance Sensor in this section.

(5)
If all previous tests prove good, replace speed­
ometer.

8E
- 12
INSTRUMENT PANEL
AND
GAUGES

•
CLUSTER AND GAUGE
SERVICE
PROCEDURES

INDEX
page
Cluster Bezel
12

Cluster
Mask
and
Lens
12
Fuel Gauge
13

Instrument
Cluster Assembly
12

Lamp Bulb Replacement—Message Center
..... 15

CLUSTER
BEZEL
REMOVAL
(1) Disconnect negative cable from battery.
(2) Tape
or
cover steering column
to
prevent dam­
age
to
paint.
(3) Remove
2
screws and remove map lamp.

CAUTION:
Map
lamp must
be
removed
to
prevent

damage
to
instrument panel.

(4) Remove
6
screws which attach cluster bezel
to

base panel (Fig.
1).
Make sure
the
screw below
the
Heater-A/C control
is
removed.
(5)
Place column shift lever
in
Position
"1".

(6) Remove bezel
by
pulling
top
edge rearward
to

clear brow. Disengage attaching clips around bottom
of bezel
and
complete removal
of
bezel.
(7)
If
bezel
is
equipped with
a
four wheel drive
in­

dicator, remove bulb socket
as
bezel
is
removed.
(8) Disconnect message center wires.

INSTRUMENT
CLUSTER BEZEL
J938E-51
Fig.
1 instrument
Cluster
Bezel

INSTALLATION
(1) Connect bulb socket
for
four wheel drive indi­
cator
if
equipped.

(2)
Connect message center wires.
(3) Engage attaching clips around bottom
of
bezel,
roll bezel into position.
(4) Install
6
mounting screws. page

Lamp Bulbs
. . 15
Printed
Circuit
Board
13

PRND21
Indicator
. 15

Specifications
15

Speedometer/Odometer
14

(5)
Install map lamp.
(6) Remove tape from steering column.
(7) Connect negative cable
to
battery.

CLUSTER
MASK AND LENS REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove cluster bezel.
(3) Remove
8
screws holding mask
and
lens.
(4) Remove mask
and
lens.

INSTALLATION
(1) Position mask
and
lens.
(2) Install
8
screws.
(3) Install cluster bezel.
(4) Connect negative cable
to
battery.

INSTRUMENT CLUSTER ASSEMBLY
(Fig.
2)

REMOVAL
(1) Disconnect negative cable from battery.
(2) Tape
or
cover steering column
to
prevent dam­
age
to
paint.
(3) Remove bezel.
(4) Remove lower steering column cover
4
screws.

(5)
Spread upper steering column cover
out of
the
locking tangs
and
slide downward. (6) Disconnect PRND21 actuator cable from steer­
ing column
if
equipped.
(7) Loosen heater
and
A/C control. Pull rearward
to clear forward mount
on
cluster housing.
(8) Remove
6
screws that retain cluster. Pull clus­
ter rearward
and
disconnect
2
large connectors.
(9) Remove cluster.

INSTALLATION
(1) Connect
2
large connectors
to
cluster.
(2) Position cluster
to
instrument panel and install
6 retaining screws.
(3) Install heater A/C control.
(4) Connect PRND21 actuator
to
steering column
if

equipped.

(5)
Position upper steering column cover
and
slide
upward until tangs snap into place.

INSTRUMENT PANEL
AND
GAUGES
8E - 13

INSTRUMENT
PANEL MAP LAMP
BRACKET
HEADLAMP
SWITCH

CLUSTER

ASSEMBLY

HEADLAMP

SWITCH
MOUNTING
NUT CARGO LAMP
SWITCH

BEZEL
AND
APPLIQUE

HEADLAMP
KNOB
AND
STEM

BRACKET-AAAP LAMP
MOUNTING

Fig.
2 Instrument
Panel
(6) Position lower steering cover and install 4
screws.

(7)
Install bezel.
(8)
Remove protective cover from steering column.
(9) Connect negative cable to battery. (10) Check to see that all instruments are func­
tioning properly.

PRINTED CIRCUIT BOARD
A visual inspection of the conductors should be
made for cracks or damaged circuits. If no visual
damage is evident, each circuit should be tested for continuity with an ohmmeter or a test light. Should an open circuit be detected, the printed circuit board
should be replaced.
REMOVAL (FIG. 3J (1) Remove instrument cluster. See cluster re­
moval.

(2)
Remove lamp socket assemblies.
(3) Remove gauge mounting screws and remove
gauges.
(4) Remove printed circuit board mounting screws.
(5)
Remove printed circuit board from cluster hous­
ing.
HEADLAMP

SWITCH
BEZEL
CLUSTER MASK AND LENS
J928E-46
Cluster
and
Switches

INSTALLATION

CAUTION:
Do not overtighten mounting
screws
or

damage
to circuit
board
and/or
cluster
housing
will

occur.

(1) Position printed circuit board on cluster hous­
ing, install mounting screws and tighten.
(2)
Install gauges.
(3) Install lamp socket assemblies. Be sure illumi­
nation lamp diffusers are installed. (4) Install instrument cluster.

FUEL GAUGE

TEMPERATURE
GAUGE VOLTAGE GAUGE
OIL
PRESSURE
GAUGE
It is not necessary to remove instrument clus­
ter from vehicle for gauge replacement. When removing gauge assemblies (Fig. 4) from
cluster, gauge must be pulled straight out, not
twisted, or damage to gauge pin and/or printed cir­ cuit board may result. (1) Disconnect negative cable from battery.

(2)
Remove bezel. Refer to Cluster Bezel Removal. (3) Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal.

8E
- 14
INSTRUMENT
PANEL
AND
GAUGES

•
VOLTAGE
GAUGE
Fig. 3 instrument Cluster Printed Circuit Board

SPEEDOMETER OIL
PRESSURE

GAUGE
TEMPERATURE GAUGE
FUEL
GAUGE

Fig. 4 Cluster With Mask Removed
J908E-69

(4)
Remove gauge mounting screws.
(5) Pull gauge rearward to remove.
For Installation, reverse Removal procedures.

SPEEDOMETER/ODOMETER
It is not necessary to remove instrument clus­
ter from vehicle for speedometer replacement. When removing speedometer (Fig. 4) from cluster,
gauge must be pulled straight out, not twisted, or
damage to gauge pin and/or printed circuit board
may result. (1) Disconnect negative cable from battery.
(2) Remove bezel. Refer to Cluster Bezel Removal.
(3) Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal. (4) Remove mounting screws retaining speedome­
ter/odometer to housing.
(5) Pull speedometer/odometer rearward to remove.
For Installation, reverse Removal procedures.

•

INSTRUMENT PANEL
AND
GAUGES
8E - 15
PRND21 INDICATOR

REMOVAL
(1) Remove bezel. Refer to Cluster Bezel Removal.

(2)
Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal. (3) Remove cluster assembly. Refer to Instrument
Cluster Removal. (4) Remove screws attaching PRND21 mechanism
to cluster housing.
(5)
Remove PRND21 mechanism.
INSTALLATION (1) Position PRND21 mechanism to cluster hous­
ing. (2) Install mounting screws.

(3)
Install cluster assembly. (4) Install mask-lens.

(5)
Install bezel.

LAMP BULBS
CLUSTER ILLUMINATION LAMPS TURN SIGNAL INDICATOR LAMPS
LOW OIL PRESSURE INDICATOR LAMP
HIGH BEAM INDICATOR LAMP CHECK ENGINE LAMP
SEAT BELT WARNING LAMP
REMOVAL (1) Disconnect negative cable from battery.
(2) Remove instrument cluster. See cluster re­
moval.
(3)
Twist lamp socket assembly and remove from
printed circuit board. (4) Remove bulb from socket.
INSTALLATION (1) Install bulb into socket.
(2) Install socket assembly into printed circuit
board.
(3)
Position cluster into place in panel. See cluster
installation. (4) Connect battery negative cable.

LAMP BULB REPLACEMENT—MESSAGE CENTER

REMOVAL (1) Disconnect battery negative cable.
(2) Remove instrument cluster bezel assembly. Re­
fer to Instrument Cluster removal.
(3)
Twist lamp socket assembly and remove from
printed circuit board. (4) Remove bulb from socket.
INSTALLATION (1) Install bulb into socket assembly. (2) Install lamp socket assembly into printed cir­
cuit board.

(3)
Install Instrument Cluster bezel assembly to
instrument panel. Refer to Instrument Cluster instal­
lation.
(4) Connect negative cable from battery.
FOUR WHEEL DRIVE INDICATOR LAMP (1) Pull bulb and socket assembly from rear of
housing. (2) Remove bulb from socket.

(3)
Reverse removal procedures to install.

SPECIFICATIONS
Fuel
Gauge Calibration
Mntar Position Resistance
Empty Graduation 90
ohms
± 3
ohms
Empty Stop
Greater
than
96.5 ohms

Full
Graduation 12 ohm
± 3
ohms

Full
Stop
Less
than
8
ohms

1/2
45.3 ohms
± 3
ohms

Temperature
Gauge
Calibration

Pointer
Position Resistance
Cold Graduation 655 ohms
Hot Graduation 64 ohms
Oil Pressure Gauge Calibration

Pointer
Position Resistance
Low Graduation 100 ohms
High Graduation 12 ohms

J908E-58

8E - 16 INSTRUMENT PANEL AND GAUGES
• SWITCH AND
PANEL
COMPONENT
SERVICE

INDEX

page

Ash
Tray
20
Cigar
Lighter
........................ 20
Four
Wheel Drive
Indicator
19

Fuse
Block
and
Flashers
................... 19

Glove
Box 21

Heater A/C Control
17
page

Heater Control
16

Hood
Release
19
Illumination
Bulb Replacement
22

Message
Center Module
................... 18

Steering Column Lowering
and
Raising
16
Switches
17
DISCONNECT NEGATIVE CABLE FEOM
BATTERY IN ENGINE COMPAETMENT BE­ FORE SERVICING INSTRUMENT PANEL.
STEERING COLUMN LOWERING AND RAISING When servicing the instrument panel and the Low­
ering and Raising of the steering column is required,
the following is the procedure for doing so: This procedure is not for removing and replac­
ing the steering column. Refer to Group - 19 Steering of this manual for the removal and re­
placement procedures.

LOWERING STEERING COLUMN
(1) Disconnect negative cable from battery.

(2)
Remove 3 toe plate nuts and washers (Fig. 1).
(3) Remove 1 toe plate screw.
(4) Remove 4 screws attaching lower steering col­
umn cover and remove cover. The fuse block is at­
tached to this cover and should be supported when cover is removed.
(5) Spread upper steering column cover out of lock­
ing tangs and slide downward.
(6)
Disconnect cable from shift indicator bracket.

(7)
Remove 2 nuts and washers attaching steering
column bracket to instrument panel steering column support bracket.
(8)
Allow column to lower and rest on seat.
STEERING

COLUMN SUPPORT

WASHER
AND NUT

Fig.
1 Steering
Column
Mounting
RAISING STEERING COLUMN

(1) Raise steering column assembly against the in­
strument panel support bracket. (2) Install 2 steering column bracket washers and
nuts (Finger Tighten Only).

CAUTION:
Check that
all
wiring
is
clear
and not
pinched.

(3) Tighten the 2 bracket nuts to 12 Nnn-(110 in.
lbs.) torque. (4) Slide toe plate into position, install attaching
screw, tighten to 4 N®m (35 in. lbs.).
(5) Install toe plate nuts and washers and tighten
to 23 N*m (200 in. lbs.).
(6)
Connect cable to shift indicator bracket.

(7)
Position upper steering column cover and slide
upward until tangs snap into place.
(8) Install fuse block to cover.

(9)
Position lower steering column cover and in­
stall 4 attaching screws.
HEATER CONTROL

REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval). (3) Remove 2 control attaching screws. (4) Pull control rearward.
(5) Disconnect illumination lamp, and wire connec­

tions.
(6)
Disconnect control cables.

(7)
Remove control.

INSTALLATION
(1) Position control near panel.
(2) Connect control cables to control (see Heater
A/C Section). (3) Connect illumination lamp, and wire connec­

tors.

(4) Push control into panel.
(5) Install 2 control mounting screws.

(6)
Install bezel.

(7)
Install map lamp.

INSTRUMENT
PANEL
AND
GAUGES
8E - 17

HEATER
A/C
CONTROL

REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(3) Remove 2 control attaching screws.
(4) Pull control rearward.
(5) Disconnect blower switch wiring.
(6) Disconnect wires to pushbutton switch (three
connectors). (7) Disconnect illumination lamp.
(8) Disconnect vacuum harness.
(9) Disconnect temperature cable.
(10) Remove control.

INSTALLATION
(1) Position control near panel.
(2) Connect temperature cable (see Group 24 -
Heating and Air Conditioning).
(3) Connect vacuum harness. (4) Connect illumination lamp.
(5) Attach 3 wire connectors to pushbutton switch.
(6) Connect wires to blower motor switch.
(7) Push control into panel.
(8) Install 2 control mounting screws.
(9) Install cluster bezel.
(10) Install map lamp.
INSTRUMENT
PANEL SWITCHES

HEADLAMP
SWITCH
(FIG. 2)

REMOVAL
(1) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(2) Reaching under instrument panel, depress knob
and stem release button located on bottom of switch
housing. At the same time pull knob and stem as­ sembly out of switch housing located on front of
panel.
(3) Remove power mirror switch knob by pulling
straight off.
(4) Remove bezel.
(5) From front of panel remove spanner nut,
mounting switch to panel. (6) Reaching under instrument panel, lower switch
down far enough to disconnect electrical leads. (7) Remove switch.

INSTALLATION
(1) Connect all electrical leads to switch.
(2) Guide switch into position in panel, install
spanner nut and tighten securely.
(3) Install bezel.
(4) Install power mirror switch knob.
(5) Insert knob and stem assembly into switch.
AAAP LAMP

BRACKET

HEADLAMP SWITCH
CLUSTER

ASSEMBLY

HEADLAMP
SWITCH MOUNTING NUT
CARGO
LAMP SWITCH

BEZEL
AND APPLIQUE
HEADLAMP
KNOB AND STEM
BRACKET-MAP LAMP MOUNTING HEADLAMP
SWITCH BEZEL
CLUSTER AAASK AND LENS
J928E-46

Fig.
2 Instrument
Panel
Switches

8E
- 18
INSTRUMENT PANEL
AND
GAUGES
—
•

Fig.
3 Overdrive
Lockout
Switch
and
Message
Center
Module
J918E-32

Fig.
4
Message
Center Printed Circuit
Board—Automatic
Transmission

INSTALLATION
(1) Position lockout switch into module and push
until retaining tabs lock into place.
(2) Connect switch connector.

(3)
Install instrument cluster bezel to panel.

MESSAGE
CENTER MODULE
(Fig. 3) REMOVAL (1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(3)
Reach behind bezel and disconnect lockout
switch (if equipped) and message center connectors.

(4)
Remove 3 module retaining screws and one clip
and pull module from bezel.

(6)
Install cluster bezel.

(7)
Check operation of switch.
POWER MIRROR SWITCH Refer to Group 8T - Power Mirrors
CARGO LAMP SWITCH

REMOVAL
(1) Locate chime module. Grasp chime module and
twist it to remove it from the bracket. (2) Remove wiring connector from cargo lamp
switch.
(3)
Depress lock tabs on switch and push it out of
the instrument panel.

INSTALLATION
(1) Hold wiring connector in switch opening.
(2) Push switch on to wiring connector.

(3)
Continue to push until switch snaps into place.

(4)
Install chime module on to bracket.
MAP LAMP SWITCH

REMOVAL
(1) Remove 2 attaching screws.
(2) Drop assembly down and remove wiring con­
nector, then remove map lamp assembly.

INSTALLATION
(1) Connect wiring connector to lamp assembly. (2) Position map lamp assembly to panel and in­
stall 2 mounting screws.
GLOVE BOX LAMP SWITCH

REMOVAL
(1) Open glove box until stops in bin rest against
instrument panel.
(2) Depress stops to clear instrument panel and
continue pivoting glove box assembly downward.

(3)
Disconnect wire to switch.

(4)
Snap switch out of panel.

INSTALLATION
(1) Snap switch into panel.
(2) Connect wire to switch.

(3)
Depress stops and close glove box door.
OVERDRIVE LOCKOUT SWITCH (FIG. 3)

REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(3)
Reach behind bezel and disconnect lockout
switch connector.

(4)
Depress retaining tabs on top and bottom of
switch and pull switch out of module.

•

INSTRUMENT PANEL
AND
GAUGES
8E - 19

MESSAGE
CENTER
PRINTED CIRCUIT BOARD
J918E-33

Fig.
5
Message
Center Printed Circuit
Board—Manual
Transmission

LOW FUEL MODULE
>

PRINTED CIRCUIT BOARD
J918E-34

Fig.
6
Message
Center Printed Circuit
Board—Diesel
(5) Remove overdrive lockout switch from module.

INSTALLATION
(1) Install overdrive lockout switch into module.
(2) Position module on bezel and install screws and

clip.

(3) Connect lockout switch and message center
connectors.
(4) Install instrument cluster bezel to panel.
(5) Install map lamp.

FUSE
BLOCK AND
FLASHERS

FUSE
BLOCK
The fuse block is located directly below the steer­
ing column, on the lower steering column cover.

REMOVAL
Push fuse block locking tab on column cover down­
ward and lower fuse block. The following components
plug into the fuse block.
• Fuses. • 30 amp circuit breakers.
• Turn signal flasher. • Horn relay.
• Hazard Warning Flasher.

INSTALLATION
(1) Position fuse block to steering column cover. (2) Push locking tab to lock fuse block in position.

HOOD
RELEASE

REMOVAL
(1) Disengage cable from hood latch in engine com­
partment. (2) Remove 4 screws holding handle assembly to
instrument panel.
(3) Remove assembly by pulling cable rearward
through dash panel grommet.

INSTALLATION
(1) Feed cable assembly forward through dash
panel grommet.
(2) Mount handle assembly to instrument panel
with four screws.
(3) Connect cable to hood latch.

FOUR
WHEEL
DRIVE
INDICATOR
REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(3) Remove 2 screws and remove indicator from be­
zel (Fig. 7).
o

J928E-48

Fig.
7
Four
Wheel
Drive Indicator
Bezel