instrument panel CHRYSLER VOYAGER 2004 Service Manual

CUP HOLDER
REMOVAL
(1) Remove the screw access cover from the bottom
of the center bezel.
(2) Remove the center bezel attaching screws.
(3) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out on the edge of the instru-
ment panel center bezel. Hang off to the side leaving
the accessory switches connected.
(4) Pull the cup holder assembly rearward to dis-
engage the rear guide studs from instrument panel
(Fig. 2).
(5) Remove the cup holder assembly from lower
instrument panel.
INSTALLATION
(1) Ensure the cup holder assembly is in the closed
position. The cup holder assembly must be installed
as an assembly to ensure proper track position.
(2) Place the cup holder assembly into position in
the lower instrument panel and slide into opening
until the rear guide struts snap into place (Fig. 2).
(3) Install the center bezel.
(4) Install the center bezel attaching screws
(5) Install the screw access cover to the bottom of
the center bezel.
GLOVE BOX
REMOVAL
(1) Open glove box.(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
INSTALLATION
(1) Place glove box in position.
(2) Engage hinge hooks into instrument panel and
pivot glove box upward.
(3) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(4) Close glove box door.
GLOVE BOX LATCH
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
(5) Remove the assembly screws.
(6) Disassemble the glove box.
(7) Separate the latch from the glove box assembly.
INSTALLATION
(1) Install the latch onto the glove box assembly.
(2) Assemble the glove box.
(3) Install the assembly screws.
(4) Engage hinge hooks into instrument panel and
pivot glove box upward.
(5) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(6) Close glove box door.
GLOVE BOX LATCH STRIKER
REMOVAL
(1) Open glove box door.
(2) Remove screws holding lock striker to instru-
ment panel.
(3) Remove glove box latch striker.
INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
Fig. 2 CUP HOLDER
1 - LOWER INSTRUMENT PANEL
2 - CUP HOLDER AND TRACK
23 - 64 INSTRUMENT PANELRS

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) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(14) Remove the two screws to the hood release
handle.
(15) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).
(16) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(17) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 4).
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.(19) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(20) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 5).
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt (Fig. 6).
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) 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.
(25) 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.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) 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.
(32) Feed power mirror wire harness inboard
through the A-pillar.
(33) Remove the bolts attaching the instrument
panel frame to the dash panel below windshield
opening.
(34) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
panel up off the HVAC so you won't damage the seal-
ing surface of the distribution duct.
If the instrument panel is being replaced, transfer
all parts to the new instrument panel assembly.
RSINSTRUMENT PANEL23-65

INSTALLATION
(1) With the help of an assistant place the instru-
ment panel into vehicle on roll down bolts. As you
roll the instrument panel up, lift the instrument
panel up so the duct work does not bind or bend and
you can set it down on the HVAC housing to get the
proper seal at the distribution duct. Get one bolt
started in the dash panel.
(2) Install the left and right side A-pillar retaining
bolts. There are two 13 mm bolts and one 10 mm
bolt. The 10 mm bolts need to be installed first to
insure proper positioning of the Instrument panel in
the vehicle. Start the right side 10 mm bolt first (Fig.
6).(3) Feed power mirror wire harness outboard
through the A-pillar.
(4) Install both the left and right power mirrors:
(a) Connect the wire connector and install the
mirror onto the vehicle.
(b) Install the three torx retaining screws.
(c) Using a firm push, snap the mirror trim
cover into place.
(5) Connect the two front window defroster grid
wire connectors. One on each side of vehicle.
(6) Tighten the right side roll down bolt.
(7) Install the right end cover. Position over retain-
ing slots and firmly snap into place.
(8) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(9) Install the bolts attaching the instrument
panel frame to the dash panel below windshield
opening.
(10) Install the instrument panel top cover. Slide
the front edge of the top cover toward dash panel,
and firmly snap down the rear edge of the to cover to
engage clips.
(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Tighten the left side roll down bolt.
(13) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
Fig. 3 INSTRUMENT PANEL CENTER STACK RIGHT
& LEFT REINFORCEMENTS
1 - INSTRUMENT PANEL
2 - CENTER STACK RIGHT & LEFT REINFORCEMENT
Fig. 4 INSTRUMENT PANEL LOWER
REINFORCEMENT
1 - LOWER RIGHT REINFORCEMENT
2 - STEERING WHEEL ASSEMBLY
Fig. 5 STEERING COLUMN MOUNTING BRACKET
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL STEERING BRACKET
3 - DASH PANEL REINFORCEMENT
4 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
23 - 66 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

(14) Install the four nuts retaining the steering
column and lower to the floor (Fig. 5).
(15) Connect the Occupant Restraint Controller
(ORC) harness connector.
(16) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(17) Install the screws attaching the instrument
panel reinforcement (Fig. 4).
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(22) Clip the Data Link Connector (DLC) to the
steering column backing plate.
(23) Install the eight screws to the steering column
backing plate.(24) Install the four screws to the lower steering
column cover.
(25) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(26) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(27) Install the two screws to each right and left
cowl trim covers.
(28) Connect the wire connectors to the Passenger
Airbag.
(29) Install the bolts attaching the lower supports
to the floor pan.
(30) Install the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(31) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(32) Connect the battery negative cable.
Fig. 6 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - FIVE ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
RSINSTRUMENT PANEL23-67
INSTRUMENT PANEL ASSEMBLY (Continued)

INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel
gently pry outward.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 7).
(4) Remove the two center bezel attaching screws.
(5) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.
(6) Disconnect the wire connectors to the accessory
switches and HVAC control.
(7) Remove the instrument panel center bezel from
the vehicle.
INSTALLATION
(1) Place center bezel near opening and connect
the wire connectors to the accessory switches and
HVAC control.
(2) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place (Fig. 7).
(3) Install the two center bezel attaching screws.
(4) Install the screw access cover to the bottom of
the center bezel.
INSTRUMENT PANEL END CAP
REMOVAL
(1) Open passenger side front door.
(2) Using a trim stick, disengage clips holding end
cover to instrument panel (Fig. 8).
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place (Fig. 8).
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips attaching
rear edge of top cover to instrument panel (Fig. 9).
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Pull top cover rearward to disengage hooks
attaching front of top cover to instrument panel.
(4) Remove top cover from vehicle.
Fig. 7 INSTRUMENT PANEL CENTER BEZEL
1 - LOWER INSTRUMENT PANEL
2 - INSTRUMENT PANEL CENTER BEZEL
3 - CUPHOLDER
Fig. 8 INSTRUMENT PANEL END CAP
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL END CAP
23 - 68 INSTRUMENT PANELRS

INSTALLATION
(1) Place instrument panel top cover in position on
vehicle (Fig. 9).
(2) Push top cover forward to engage hooks attach-
ing front of top cover to instrument panel.
(3) Engage clips attaching rear edge of top cover to
instrument panel.
(4) Pull top cover rearward.
(5) Install A-pillar trim.
LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 10).
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2) Install the lower console into the vehicle (Fig.
10).
(3) Slide console forward around instrument panel
supports.
(4) Install the screws attaching lower console to
floor bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Remove the right end cover.
(2) Remove the lower steering column cover.
(3) Remove the center bezel.
(4) Remove the lower console.
(5) Remove the cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Remove the eighteen screws holding the lower
instrument panel to the reinforcement frame (Fig.
11).
(10) Remove the lower instrument panel from
vehicle.
INSTALLATION
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Install the lower instrument panel into the
vehicle (Fig. 11).
(2) Install the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(3) Install the glove box lamp.
(4) Install the glove box latch striker.
(5) Install the glove box.
(6) Install the cup holder and track.
(7) Install the lower console.
Fig. 9 INSTRUMENT PANEL TOP COVER
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT PANEL
Fig. 10 INSTRUMENT PANEL FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR CONSOLE
RSINSTRUMENT PANEL23-69
INSTRUMENT PANEL TOP COVER (Continued)

(8) Install the center bezel.
(9) Install the lower steering column cover.
(10) Install the right end cover.
LOWER STEERING COLUMN
COVER
REMOVAL
(1) Remove the four screws attaching the lower
steering column cover to instrument panel (Fig. 12).
(2) Remove the lower steering column cover from
the vehicle.
INSTALLATION
(1) Install the lower steering column cover into the
vehicle (Fig. 12).
(2) Install the four screws attaching the lower
steering column cover to instrument panel.
STEERING COLUMN COVER
BACKING PLATE
REMOVAL
(1) Remove lower steering column cover (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(2) Remove the park brake release handle link
from the park brake release handle.
(3) Remove screws attaching lower steering col-
umn backing plate to instrument panel (Fig. 12).
(4) Unclip the Data Link Connector (DLC) from
the lower steering column backing plate.
(5) Remove lower steering column backing plate
from vehicle.
INSTALLATION
(1) Install the steering column cover backing plate
into vehicle (Fig. 12).
(2) Clip the Data Link Connector (DLC) to the
steering column cover backing plate
(3) Install the screws attaching steering column
cover backing plate to instrument panel.
(4) Connect the park brake release handle link to
the park release handle.
(5) Install the lower steering column cover (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
OVER STEERING COLUMN
COVER
REMOVAL
(1) Taking a firm grasp of the over steering col-
umn cover front edge, give a quick upward pulling
motion to disengage the cover from the instrument
panel (Fig. 13).
(2) Remove the over steering column cover from
the vehicle.
INSTALLATION
(1) Place the over steering column cover into posi-
tion over the retaining slots and firmly snap into
place (Fig. 13).
Fig. 11 LOWER INSTRUMENT PANEL
1 - INSTRUMENT PANEL
2 - LOWER INSTRUMENT PANEL
Fig. 12 LOWER STEERING COLUMN COVER
1 - STEERING COLUMN COVER BACKING PLATE
2 - STEERING COLUMN COVER
23 - 70 INSTRUMENT PANELRS
LOWER INSTRUMENT PANEL (Continued)

INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1) Remove the instrument cluster (Fig. 14). (Refer
to 8 - ELECTRICAL/INSTRUMENT CLUSTER -
REMOVAL)
(2) Remove the message center (Fig. 14). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 14). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 14). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 14). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 15).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 15).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.
(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 14).
Fig. 13 OVER STEERING COLUMN COVER
1 - INSTRUMENT PANEL OVER STEERING COLUMN COVER
2 - INSTRUMENT PANEL
Fig. 14 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - MESSAGE CENTER
3 - TOP COVER
4 - PAD AND PANEL ASSEMBLY
5 - LOWER CONSOLE
6 - LOWER PANEL
7 - RADIO
8 - HEADLAMP SWITCH
Fig. 15 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
RSINSTRUMENT PANEL23-71
OVER STEERING COLUMN COVER (Continued)

INSTALLATION
(1) Position the pad & panel assembly onto the
instrument panel support structure.
(2) Install the 19 screws along the lower edge of
the pad & panel assembly.
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws.
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube.
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13) Install the message center. (Refer to 8 -
ELECTRICAL/MESSAGE CENTER - INSTALLA-
TION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
23 - 72 INSTRUMENT PANELRS
INSTRUMENT PANEL TOP PAD ASSEMBLY (Continued)

A-PILLAR LOWER EXTENSION
TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove A-pillar extension trim from vehicle by
disengaging hidden clips (Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle (Fig. 1).
(2) Install instrument panel side cover.
A-PILLAR TRIM
REMOVAL
(1) Remove the assist handle if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE -
REMOVAL)
(2) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(3) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.(5) Install the assist handle, if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - INSTAL-
LATION)
ASSIST HANDLE
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
B-PILLAR LOWER TRIM
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt attaching lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
Fig. 1 A-PILLAR LOWER EXTENSION TRIM
1 - FRONT LOWER EXTENSION TRIM
2 - FRONT EXTENSION TRIM TO INSTRUMENT PANEL
RETAINER
3 - CLIP
4 - COWL TRIM PANEL
Fig. 2 A-PILLAR TRIM
1 - A-PILLAR
2 - CLIPS
23 - 74 INTERIORRS