steering CHRYSLER VOYAGER 2002 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 1836 of 2399
(3) Install steering column lower shroud.
(4) Install knee bolster (Fig. 311).
(5) Install instrument panel lower silencer (Fig.
312).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)SOLENOID/PRESSURE
SWITCH ASSY
DESCRIPTION
The Solenoid/Pressure Switch Assembly (Fig. 313)
is external to the transaxle and mounted to the
transaxle case. The assembly consists of four sole-
noids that control hydraulic pressure to the LR/CC,
2/4, OD, and UD friction elements. The reverse
clutch is controlled by line pressure from the manual
valve in the valve body. The solenoids are contained
within the Solenoid/Pressure Switch Assembly, and
can only be serviced by replacing the assembly.
The solenoid assembly also contains pressure
switches that monitor and send hydraulic circuit
information to the TCM. Likewise, the pressure
switches can only be service by replacing the assem-
bly.
Fig. 311 Knee Bolster
1 - KNEE BOLSTER
Fig. 312 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCERFig. 313 Solenoid/Pressure Switch Assembly
1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 279
SHIFT INTERLOCK SOLENOID (Continued)
ProCarManuals.com
Page 1962 of 2399
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL VIBRATION.....................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................5
STANDARD PROCEDURE - TIRE AND
WHEEL MATCH MOUNTING..............5
STANDARD PROCEDURE - TIRE AND
WHEEL ROTATION.....................7
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)....................7
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL).......................7
INSTALLATION
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (ALUMINUM WHEEL)..........8
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (STEEL WHEEL)..............8
TIRE PRESSURE MONITORING (TPM)
DESCRIPTION..........................9
OPERATION............................9
SENSOR - TPM
DESCRIPTION.........................10
OPERATION...........................10
CAUTION.............................10
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR............................10
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN....................10
REMOVAL.............................11
INSTALLATION.........................11
TIRES
DESCRIPTION
DESCRIPTION - TIRE..................13
DESCRIPTION - RADIAL-PLY TIRES.......13DESCRIPTION - REPLACEMENT TIRES....14
DESCRIPTION - SPARE TIRE
(TEMPORARY).......................14
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE . . . 14
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD...............................14
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS..........................14
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS.........................14
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES.........................14
STANDARD PROCEDURE - TIRE
PRESSURE FOR HIGH SPEED
OPERATION.........................17
STANDARD PROCEDURE - TIRE LEAK
REPAIRING..........................17
CLEANING - TIRES.....................17
WHEELS
DESCRIPTION - WHEEL..................17
DIAGNOSIS AND TESTING - WHEEL
INSPECTION.........................18
CLEANING - ALUMINUM WHEEL CARE......18
SPECIFICATIONS
WHEEL.............................19
WHEEL COVER
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................19
WHEEL MOUNTING STUDS - FRONT
REMOVAL.............................20
INSTALLATION.........................21
WHEEL MOUNTING STUDS - REAR
REMOVAL.............................21
INSTALLATION.........................22
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and force varia-
tion can cause vehicles to exhibit steering wheel
vibration.
VISUAL INSPECTION
Visual inspection of the vehicle is recommended
prior to road testing or performing any other proce-
dure. Raise vehicle on a suitable hoist. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
RSTIRES/WHEELS22-1
ProCarManuals.com
Page 1963 of 2399
Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
unique wheel weights. They are designed to fit the
contour of the wheel (Fig. 1).
²Inspect tires and wheels for damage, mud pack-
ing and unusual wear; correct as necessary.
²Check and adjust tire air pressure to the pres-
sure listed on the label attached to the rear face of
the driver's door.
ROAD TEST
Road test vehicle on a smooth road for a least five
miles to warm tires (remove any flat spots). Lightly
place hands on steering wheel at the 10:00 and 2:00
positions while slowly sweeping up and down from 90 to
110 km/h (55 to 70 mph) where legal speed limits allow.
Observe the steering wheel for:
²Visual Nibble (oscillation: clockwise/counter-
clockwise, usually due to tire imbalance)
²Visual Buzziness (high frequency, rapid vibra-
tion up and down)
To rule out vibrations due to brakes or powertrain:
²Lightly apply brakes at speed; if vibration occurs
or is enhanced, vibration is likely due to causes other
than tire and wheel assemblies.
²
Shift transmission into neutral while vibration is
occurring; if vibration is eliminated, vibration is likely
due to causes other than tire and wheel assemblies.
For brake vibrations, (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/ROTORS -
DIAGNOSIS AND TESTING).
For powertrain vibrations, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE - DIAGNOSIS AND TESTING).
For tire and wheel assembly vibrations, continue
with this diagnosis and testing procedure.
TIRE AND WHEEL BALANCE
(1) Balance the tire and wheel assemblies as nec-
essary following the wheel balancer manufacturer's
instructions and using the information listed in Stan-
dard Procedure - Tire And Wheel Balance. (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE)
(2) Road test the vehicle for at least 5 miles, fol-
lowing the format described in Road Test.
(3) If the vibration persists, continue with this
diagnosis and testing procedure.
TIRE AND WHEEL RUNOUT/MATCH MOUNTING
(1)System Radial Runout.This on-the-vehicle
system check will measure the radial runout includ-
ing the hub, wheel and tire.
(a) Raise vehicle so tires clear floor. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(b) Apply masking tape around the circumfer-
ence of the tire in the locations to be measured
(Fig. 2). Do not overlap the tape.
(c) Check system runout using Dial Indicator
Set, Special Tool C-3339A with 25-W wheel, or
equivalent. Place the end of the indicator against
each taped area (one at a time) (Fig. 2) and rotate
the tire and wheel. System radial runout should
not exceed 0.76 mm (0.030 inch) with no tread
ªdipsº or ªsteps.º Tread ªdipsº and ªstepsº can be
identified by spikes of the dial indicator gauge.
²Tread9dips9; Rapid decrease then increase in
dial indicator reading over 101.6 mm (4.0 inch) of
tread circumference.
²Tread9steps9; Rapid decrease or increase in dial
indicator reading over 101.6 mm (4.0 inch) of tread
circumference.
(d) If system runout is excessive, re-index the
tire and wheel assembly on the hub. Remove
assembly from vehicle and install it back on the
hub two studs over from original mounting posi-
tion. If re-indexing the tire and wheel assembly
corrects or reduces system runout, check hub
runout and repair as necessary (Refer to 5 -
BRAKES - BASE/HYDRAULIC/MECHANICAL/
ROTORS - DIAGNOSIS AND TESTING).
(e) If system runout is still excessive, continue
with this diagnosis and testing procedure.
(2)Tire and Wheel Assembly Radial Runout.
This radial runout check is performed with the tire
and wheel assembly off the vehicle.
(a) Remove tire and wheel assembly from vehicle
and install it on a suitable wheel balancer.
(b) Check system runout using Dial Indicator
Set, Special Tool C-3339A with 25-W wheel, or
equivalent. Place the end of the indicator against
each taped area (one at a time) (Fig. 2) and rotate
the tire and wheel. Radial runout should not
Fig. 1 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
22 - 2 TIRES/WHEELSRS
TIRES/WHEELS (Continued)
ProCarManuals.com
Page 1975 of 2399
Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. It is recommended that tires from dif-
ferent manufacturers NOT be mixed. They may be
mixed with a temporary spare tire when necessary. A
maximum speed of 80 km/h (50 mph) is recom-
mended while a temporary spare is in use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
DESCRIPTION - REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The original equipment tires provide a proper com-
bination of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
The use of tires smaller than the minimum tire
size approved for the vehicle can result in tire over-
loading and failure.
Use tires that have the approved load rating for
the vehicle and never overload them. Failure to equip
the vehicle with tires having adequate speed capabil-
ity can result in sudden tire failure and loss of vehi-
cle control.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
DESCRIPTION - SPARE TIRE (TEMPORARY)
The temporary (convenience) spare tire is designed
for emergency use only. The original tire should be
repaired and reinstalled, or replaced with a new, at
the first opportunity.
The temporary (convenience) spare tire should be
inflated to the pressure listed on its sidewall. Do not
exceed speeds of 80 km/h (50 mph) when the tempo-
rary spare tire is in use on the vehicle. Refer to the
Owner's Manual for more details.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE
Unusual tire noise can be associated with tire and
wheel vibration or irregular tire wear. For vibration,
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING). For irregular tire wear, (Refer to 22 -
TIRES/WHEELS/TIRES - DIAGNOSIS AND TEST-
ING).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
rection Chart to diagnose and correct a vehicle lead
or drift problem.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 23).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 23).
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 24).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES
The specified tire pressures have been chosen to
provide safe operation, vehicle stability, and a smooth
ride. The proper tire pressure specification can be
found on the Tire Inflation Pressure Label provided
with the vehicle (usually on the rear face of the driv-
er's door).
A quality air pressure gauge is recommended to
check tire air pressure. Tire pressure should be
checked cold once per month. Check tire pressure
more frequently when the weather temperature var-
ies widely. Tire pressure will decrease when the out-
22 - 14 TIRES/WHEELSRS
TIRES (Continued)
ProCarManuals.com
Page 1981 of 2399
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 33). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 34).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 34).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 34).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 35).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 32 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 33 Nut Tightening Sequence
Fig. 34 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
22 - 20 TIRES/WHEELSRS
WHEEL COVER (Continued)
ProCarManuals.com
Page 1982 of 2399
INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 36).(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head of
the stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 34).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 34).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the rear wheel and tire assembly.
(3) Remove the brake drum or disc brake caliper
and rotor. Refer to Brakes.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 37)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 37).
(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange.
(6) Remove lug nut from stud and remove wheel
stud from flange.
Fig. 35 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 36 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
RSTIRES/WHEELS22-21
WHEEL MOUNTING STUDS - FRONT (Continued)
ProCarManuals.com
Page 1987 of 2399
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY,
BAYBLENDDOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
23 - 4 BODYRS
BODY (Continued)
ProCarManuals.com
Page 1988 of 2399
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGSBUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-
POLYPROPYLENETPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTERTPU, HYTREL, TEXIN,
ESTANEBUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
RSBODY23-5
BODY (Continued)
ProCarManuals.com
Page 2046 of 2399
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL.............................63
INSTALLATION.........................63
CUP HOLDER
REMOVAL.............................64
INSTALLATION.........................64
GLOVE BOX
REMOVAL.............................64
INSTALLATION.........................64
GLOVE BOX LATCH
REMOVAL.............................64
INSTALLATION.........................64
GLOVE BOX LATCH STRIKER
REMOVAL.............................64
INSTALLATION.........................65
INSTRUMENT PANEL ASSEMBLY
REMOVAL.............................65
INSTALLATION.........................67
INSTRUMENT PANEL CENTER BEZEL
REMOVAL.............................68
INSTALLATION.........................68INSTRUMENT PANEL END CAP
REMOVAL.............................68
INSTALLATION.........................68
INSTRUMENT PANEL TOP COVER
REMOVAL.............................69
INSTALLATION.........................69
LOWER CONSOLE
REMOVAL.............................69
INSTALLATION.........................69
LOWER INSTRUMENT PANEL
REMOVAL.............................70
INSTALLATION.........................70
LOWER STEERING COLUMN COVER
REMOVAL.............................70
INSTALLATION.........................70
STEERING COLUMN COVER BACKING PLATE
REMOVAL.............................70
INSTALLATION.........................71
OVER STEERING COLUMN COVER
REMOVAL.............................71
INSTALLATION.........................71
CLUSTER BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(3) Remove the four bezel attaching screws (Fig.
1).
(4) Tilt the steering column in the full down posi-
tion.
(5) Pull rearward on the cluster bezel and remove.
INSTALLATION
(1) Maneuver cluster bezel over steering column
and into position (Fig. 1).
(2) Install the four bezel attaching screws.
(3) Install the Over Steering Column Bezel by
positioning it over the retaining slots and firmly
snapping it into place.
(4) Connect the battery negative cable.
Fig. 1 CLUSTER BEZEL
1 - INSTRUMENT PANEL
2 - CLUSTER BEZEL
RSINSTRUMENT PANEL23-63
ProCarManuals.com
Page 2048 of 2399
INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the steering col-
umn backing plate.
(12) Unclip the Data Link Connector (DLC) from
the steering column backing plate.
(13) Remove two screws to the left side instrument
panel silencer and remove (Fig. 4).
(14) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Remove the two screws to the hood release
handle.
(16) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 5).
(19) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(20) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(21) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 6).
(22) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(23) Loosen the left side roll down bolt (Fig. 7).
(24) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(25) If equipped with a mechanical transmission
range indicator:
(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.
(26) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(27) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(28) Remove the right end cover by pulling out-
board.
(29) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(30) Loosen the right side roll down bolt.
(31) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(32) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(33) Feed power mirror wire harness inboard
through the A-pillar.
(34) Remove the bolts attaching the instrument
panel frame to the dash panel below windshield
opening.
(35) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
RSINSTRUMENT PANEL23-65
GLOVE BOX LATCH STRIKER (Continued)
ProCarManuals.com