CHRYSLER VOYAGER 1996 Service Manual

(8) Using the indicator adjuster thumbwheel on
the indicator clip below the steering column. Rotate
the indicator thumbwheel to position the indicator
calibration arrow to the center of the N slot on the
instrument cluster mask.
(9) After the indicator has been properly adjusted,
move the shift lever through each gear position to
verify the appropriate gear position has been selected
and the slot is fully covered by the indicator. The left
edge of the indicator will just peek at the left edge of
the P slot in Park.
(10) If the indicator is not covering each of the
selected gear positions when selected, place the shift
lever back into neutral N and readjust the indicator.
Repeat the process until each gear is covered when
selected.
(11) Install the metal knee blocker panel.
(12) Install the lower steering column cover.
INSTRUMENT PANEL
The instrument panel is removed as a unit. The
steering column and wiring harnesses are assembled
into the panel before installation. Service procedures
for interior trim not related to the instrument panel
can be found in Group 23, Body.
REMOVAL
(1) Disconnect the battery, negative cable first.
(2) Remove the lower console.
(3) Remove the screw holding the lower heat duct
to the instrument panel support (Fig. 26).
(4) Disconnect the heat duct from the vehicle.
(5) Remove the bolts holding the lower supports to
the instrument panel frame (Fig. 27).(6) Remove the bolts holding the lower supports to
the floor pan.
(7) Remove the right and left end covers.
(8) Disconnect the wire connectors from the Pas-
senger Airbag Module.
(9) Remove the front door sill trim covers.
(10) Remove the A-pillar trim covers.
(11) Remove the glove box.
(12) Disconnect the antenna lead connector from
behind the glove box.
(13) Remove the lower steering column cover.
(14) Remove the knee blocker panel.
(15) Disconnect the lower two, forty pin wire har-
ness connectors, from the main Junction Block near
left cowl side panel (Fig. 28).
(16) Disconnect the instrument panel wire harness
connector from the bottom of Body Control Module.
(17) Disconnect the two forty pin connectors from
the right of the steering column (Fig. 29).
(18) Remove the clinch bolt holding upper the
steering shaft to the lower steering shaft (Fig. 29).
Fig. 25 Range Indicator Cable
Fig. 26 Heat Duct
Fig. 27 Lower Supports
NSINSTRUMENT PANEL AND SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)

(19) Separate the upper steering shaft from the
lower steering shaft.
(20) Remove the nuts holding the instrument
panel frame to the die-cast brake pedal support on
each side of the steering column.
(21) With mechanical transmission range indica-
tor:
(a) Remove the indicator cable loop.(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(22) Remove the nut holding gear shift cable
bracket to the instrument panel frame.
(23) Remove the bracket from the instrument
panel.
(24) Remove the screw holding hood release handle
to the instrument panel.
(25) Remove the bolt holding the hood release han-
dle to the instrument panel.
(26) Position the hood release handle out of the
way.
(27) Remove the instrument panel top cover.
(28) Disconnect the wire connector from the HVAC
wire harness behind the glove box area.
(29) Remove the bolts holding the instrument
panel frame to the brackets on cowl side panels (Fig.
30) and (Fig. 31).
(30) Loosen, but do not remove, the pivot bolts
holding the instrument panel to the cowl panels.
(31) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(32) Remove the instrument panel from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Fig. 28 Junction Block and Body Control Module
Connectors
Fig. 29 40 Way Connectors Location
Fig. 30 Passenger Side Instrument Panel
8E - 26 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL LEFT END COVER
REMOVAL
(1) Open driver side front door (Fig. 32).
(2) Remove lower steering column cover as neces-
sary to gain clearance for end cover removal.
(3) Remove attaching screw
(4) Disengage clips holding end cover to instru-
ment panel.(5) Remove instrument panel end cover and foam
pad covering the A/C inlet projection of the end cover
if equipped.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel removal and installation
procedures.
(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 33).
(3) Using a flat bladed tool, release the louver
housing locks tabs (Fig. 34).
(4) Release the upper left lock tab first, then the
two lower louver tabs.
(5) Applying pressure on the housing, release the
upper right lock tab and the lower right.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
LEFT LOUVER HOUSING
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel Removal and Installation
procedures.
Fig. 31 Driver's Side instrument Panel
Fig. 32 Instrument Panel Left End Cover
Fig. 33 Instrument Cluster Bezel
NSINSTRUMENT PANEL AND SYSTEMS 8E - 27
REMOVAL AND INSTALLATION (Continued)

(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 33).
(3) Using a flat bladed tool, release the louver
housing locks tabs.
(4) Release the upper left lock tab first, then the
other upper lock tab.
(5) Applying pressure on the housing, release the
lower lock tabs.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel and
align the slot of the housing with the T location pins.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
PASSENGER SIDE LOUVERS
The inner, outer louver and inner, outer housing
are serviceable.
REMOVAL
(1) Using medium flat blade tool, position it in
between the right side of louver and the housing
(Fig. 35).
(2) Twist the tool to release the pivot pin from the
louver and pull outward till released from pin.
(3) Place tool on the other side of louver and
release the other pivot pin and pull housing free from
the instrument panel. Use the same procedure for
either inner or outer louver.
INSTALLATION
The inner and outer louvers have different size
pivot pins on the housing. The outer housing has a
larger pin on the right side then the inner housing(Fig. 36). The louver have a surface cut out on the
right side of the housings to note the proper side.
(1) The right pivot pin is slotted on both housings.
So when aligning louver tab with the pin ensure that
they are lined up.
(2) Using care, apply pressure on outer edge of the
louver and push into place.
(3) Rotate louver to ensure proper engagement.
PASSENGER SIDE LOUVER OUTER HOUSINGS
REMOVAL
(1) Using a trim stick, insert trim stick between
the outer edge of the housing and the pad/panel vinyl
covering (Fig. 37).
Fig. 34 Center Louver
Fig. 35 Removing Passenger Louver
Fig. 36 Passenger Side Louver and Housings
8E - 28 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

(2) Lightly pry housing inward and by hand pull
the housing free from panel (Fig. 38).
INSTALLATION
(1) Place the slotted pin on the right side of the
opening.
(2) Set housing in to position and push into place.
The housing may need to be rocked to get the best fit
within the opening.
INSTRUMENT PANEL TOP COVER
REMOVAL
(1) Remove A-pillar trim.
(2) Using a trim stick, disengage clips holding rear
edge of top cover to instrument panel (Fig. 39).
(3) Disconnect wire harness from message center.
(4) Pull top cover rearward to disengage hooks
holding front of top cover to instrument panel.
(5) Remove top cover.
INSTALLATION
(1) Place instrument panel top cover in position on
vehicle.
(2) Push top cover forward to engage hooks to hold
front of top cover to instrument panel.
(3) Connect wire harness to message center.
(4) Engage clips to hold rear edge of top cover to
instrument panel.
(5) Pull top cover rearward.
(6) Install A-pillar trim.
INSTRUMENT PANEL RIGHT END COVER
REMOVAL
(1) Open passenger side front door (Fig. 40).
Fig. 37 Remove Housing
Fig. 38 Housing Being Removed
Fig. 39 Instrument Panel Top Cover
Fig. 40 Instrument Panel Right End Cover
NSINSTRUMENT PANEL AND SYSTEMS 8E - 29
REMOVAL AND INSTALLATION (Continued)

(2) Disengage clips holding right end cover to
instrument panel.
(3) Remove instrument panel end cover and foam
pad covering the A/C inlet projection of the end cover
if equipped.
INSTALLATION
For installation, reverse the above procedures.
JUNCTION BLOCK
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement.
(3) Disconnect four, forty-way connectors from
Junction Block (Fig. 41).
(4) Disconnect two wire connectors from bottom of
Body Control Module.
(5) Remove bolts holding Junction Block to dash
panel mounting.
(6) Remove Junction Block from mounting bracket.
(7) Remove screws holding Body Control Module to
Junction Block.
(8) Slide Body Control Module downward to dis-
connect guide studs on Junction Block from BCM
ting bracket.
(9) Separate Junction Block from Body Control
Module.
INSTALLATION
For installation, reverse the above procedures.
KNEE BLOCKER REINFORCEMENT
REMOVAL
(1) Remove lower steering column cover (Fig. 42).
(2) Remove screws holding knee blocker reinforce-
ment to instrument panel.(3) Remove reinforcement.
INSTALLATION
(1) Place reinforcement in position.
(2) Install screws to hold knee blocker reinforce-
ment to instrument panel.
(3) Install lower steering column cover.
LOWER CONSOLE
REMOVAL
(1) Remove screws holding lower console to floor
bracket and instrument panel (Fig. 43).
(2) Slide console rearward from around instrument
panel supports.
(3) Remove lower console.
Fig. 41 Junction Block
Fig. 42 Knee Blocker Reinforcement
Fig. 43 Lower Console
8E - 30 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place lower console in position.
(2) Slide console forward around instrument panel
supports.
(3) Install screws to hold lower console to floor
bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
(1) Remove the right end cover.
(2) Remove the steering column bezel.
(3) Remove the radio bezel and the HVAC control.
(4) Remove the lower console.
(5) Remove the convenience cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Disconnect the wire connector from glove box
lamp.
(10) Remove the screws holding the lower instru-
ment panel to the reinforcement frame around the
glove box opening (Fig. 44).
(11) Remove the screw holding the lower instru-
ment panel to the right side of instrument panel.
(12) Remove the screw holding the lower instru-
ment panel to the upper instrument panel at the left
side panel above the accelerator pedal.
(13) Remove the instrument cluster bezel as neces-
sary to gain access to the lower instrument panel
screws.
(14) Remove the screw holding instrument panel
to the upper panel below the instrument cluster.
(15) Remove the screws holding rear of storage
pocket to the panel support frame.
(16) Remove the screws holding the lower instru-
ment panel to the upper instrument panel from
below radio.(17) Remove the screws holding lower instrument
panel to the support frame in floor console area.
(18) Separate the lower instrument from the upper
instrument panel.
(19) Disconnect the wire connectors from back of
the 12 volt outlet base.
(20) Remove the lower instrument from vehicle.
INSTALLATION
For installation, reverse the above procedures.
LOWER STEERING COLUMN COVER
REMOVAL
(1) Remove screws holding parking brake release
handle to instrument panel (Fig. 45).
(2) Remove screws holding bottom of lower steer-
ing column cover to instrument panel (Fig. 46).
(3) Remove screw holding right side of lower steer-
ing column cover to instrument panel.
Fig. 44 Lower Instrument Panel
Fig. 45 Park Brake Release Handle
Fig. 46 Lower Steering Column Cover
NSINSTRUMENT PANEL AND SYSTEMS 8E - 31
REMOVAL AND INSTALLATION (Continued)

(4) Disengage park brake release cable case from
groove on end of release handle (Fig. 47).
(5) Disengage cable end pivot from slot on release
handle (Fig. 47).
INSTALLATION
For installation, reverse the above procedures,
MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster.
(2) Remove cluster lens.
(3) Remove screws holding mechanical transmis-
sion range indicator to back of cluster lens.
(4) Remove mechanical transmission range indica-
tor from cluster lens.
INSTALLATION
(1) Position transmission range indicator on clus-
ter lens.
(2) Install mechanical range indicator and attach-
ing screws to back of cluster lens.
(3) Install cluster lens.
(4) Install instrument cluster.
MESSAGE CENTER
REMOVAL
(1) Remove A-pillar trim.
(2) Remove instrument panel top cover. Refer to
instrument panel top cover removal procedures.
(3) Disconnect the wire connector from back of
message center.(4) Remove screws holding message center to
instrument panel top cover.
(5) Remove message center from instrument panel
top cover.
INSTALLATION
(1) Place message center in position on top cover.
(2) Install screws to hold message center to instru-
ment panel top cover.
(3) Connect wire connector into back of message
center.
(4) Install instrument panel top cover.
(5) Install A-pillar trim.
MESSAGE CENTER LAMP
REMOVAL
(1) Remove instrument panel top cover. Refer to
Instrument Panel Top Cover Removal procedures.
(2) Locate the lamp in question (Fig. 48).
(3) Remove lamp and check lamp. If lamp is good
test the power supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
OUTLET (12 VOLT) BASE
REMOVAL
(1) Look inside and note position of the retaining
bosses (Fig. 49).
(2) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(3) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 50).
(4) Disconnect the base wires.
(5) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position mount ring to the instrument panel
and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
(2) Connect wires to base. Orient base alignment
rib at 11 o'clock to mate the groove in mount ring at
the same location
(3) Push base into the bezel till it locks.
(4) Install 12 volt outlet cap and check operation of
outlet or element.
OVER STEERING COLUMN BEZEL
REMOVAL
(1) Remove the lower steering column cover.
Fig. 47 Park Brake Release Handle
8E - 32 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

(2) Remove the screws holding over steering col-
umn bezel to the cluster bezel (Fig. 51).
(3) Remove over steering column bezel from vehi-
cle.
(4) Disconnect the clips holding over column bezel
to the cluster bezel.
(5) If equipped with traction control switch, discon-
nect the wire pigtail connector from the traction con-
trol switch.
(6) Remove the over steering column bezel.
INSTALLATION
(1) Place the over steering column bezel in position
and engage clips to the cluster bezel. If equipped
Fig. 48 Message Center Lamp Location
Fig. 49 Outlet Base Removal
Fig. 50 Tool For Outlet Removal
Fig. 51 Over Steering Column Bezel
NSINSTRUMENT PANEL AND SYSTEMS 8E - 33
REMOVAL AND INSTALLATION (Continued)

with traction control switch connect the wire pigtail
before engaging clips.
(2) Install the screws to hold the over steering col-
umn bezel to the cluster bezel.
(3) Install the lower column cover.
POWER MIRROR SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 52).
(2) Disconnect wire connector from back of power
mirror switch.
(3) Disengage lock tabs above and below the mir-
ror switch.
(4) Pull power mirror switch from headlamp
switch bezel.
(5) Remove power mirror switch.
INSTALLATION
For installation, reverse the above procedures.
POWER MIRROR SWITCH LAMP
REMOVAL
(1) Remove instrument cluster bezel (Fig. 53).
(2) Rotate bulb socket counterclockwise one quar-
ter turn.
(3) Pull bulb socket from back of power mirror
switch.
INSTALLATION
For installation, reverse the above procedures.
RADIO BEZEL AND HVAC CONTROL
REMOVAL
(1) Remove convenience bin - cup holder. Refer to
Convenience Bin - Cup Holder Removal and Installa-
tion procedure in this section.(2) Insert the trim stick (special tool #C-4755)
between access cover and radio bezel, above conve-
nience bin - cup holder.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 54).
(4) Separate the access cover from the vehicle.
(5) Remove convenience bin - cup holder track.
Refer to Convenience Bin - Cup Holder Track
Removal and Installation procedures in this section.
(6) Remove the attaching screws holding bottom of
the bezel to instrument panel (Fig. 55).
(7) Remove the attaching screws holding top of the
bezel to the instrument panel.
(8) Remove the bezel from the instrument panel.
(9) Disconnect the wire connector from back of the
rear blower switch, if equipped.
(10) Disconnect the wire connector from the back
of the HVAC Control.
(11) Remove the bezel.
Fig. 52 Power Mirror Switch
Fig. 53 Power Mirror Switch Lamp
Fig. 54 Convenience Bin Access Cover
8E - 34 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)