warning DODGE RAM 2002 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 2002, Model line: RAM, Model: DODGE RAM 2002Pages: 2255, PDF Size: 62.07 MB
Page 490 of 2255
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
GEAR SELECTOR INDICATOR
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(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 instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(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 instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
Fig. 4 Gear Selector Indicator Cable Remove/Install
1 - STEERING COLUMN
2 - CABLE
3 - LOOP END
4 - LEVER
5 - ADJUSTER AND BRACKET
Fig. 5 Cluster Bulb Remove/Install
1 - INSTRUMENT CLUSTER
2 - BULB AND HOLDER
BR/BEINSTRUMENT CLUSTER 8J - 11
INSTRUMENT CLUSTER (Continued)
Page 491 of 2255
(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 over-
lay 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 instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(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 instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the lens and hood unit from the cluster
housing. Refer to CLUSTER LENS AND HOOD .
(4) Remove the rear cover from the cluster hous-
ing. Refer to CLUSTER HOUSING REAR COVER .
ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
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 indi-
cator 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. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(6) Confirm proper operation of the gear selector
indicator. Calibrate the indicator, if required. (Refer
to 19 - STEERING/COLUMN - INSTALLATION).
(7) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-Fig. 6 Instrument Cluster Components
1 - COVER
2 - HOUSING
3 - MASK AND GAUGES
4 - HOOD
5 - LENS
6 - CIRCUIT BOARD
7 - ODOMETER RESET BUTTON
Fig. 7 Cluster Housing Rear Cover Remove/Install
1 - REAR CLUSTER HOUSING COVER
8J - 12 INSTRUMENT CLUSTERBR/BE
INSTRUMENT CLUSTER (Continued)
Page 492 of 2255
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(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 elec-
tronic 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. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.
CLUSTER LENS AND HOOD
CAUTION: Do not touch the face of the gauge over-
lay 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 N´m (20 in. lbs.).
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(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 N´m (20 in. lbs.).
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).(4) Reconnect the battery negative cable.
CLUSTER HOUSING
(1) Assemble the rear cover onto the cluster hous-
ing. Refer to CLUSTER HOUSING REAR COVER .
(2) Assemble the lens and hood unit onto the clus-
ter housing. Refer to CLUSTER LENS AND HOOD .
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the instrument cluster to the instru-
ment panel.
(2) If the vehicle is equipped with an automatic
transmission, position the gear selector indicator onto
the back of the cluster housing (Fig. 3).
(3) If the vehicle is equipped with an automatic
transmission, install and tighten the two screws that
secure the gear selector indicator mechanism to the
back of the cluster housing. Tighten the screws to 2.2
N´m (20 in. lbs.).
(4) Align the instrument cluster with the cluster
opening in the instrument panel and push the cluster
firmly and evenly into place. The instrument panel
wire harness has two self-docking connectors that
will be automatically aligned with, and connected to
the instrument cluster connector receptacles when
the cluster is properly installed in the instrument
panel.
(5) Install and tighten the four screws that secure
the instrument cluster to the instrument panel (Fig.
2). Tighten the screws to 2.2 N´m (20 in. lbs.).
(6) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(7) If the vehicle is equipped with an automatic
transmission, confirm proper operation of the gear
selector indicator. Calibrate the indicator, if required.
BR/BEINSTRUMENT CLUSTER 8J - 13
INSTRUMENT CLUSTER (Continued)
Page 495 of 2255
on the instrument cluster circuit board based upon a
hard wired input to the instrument cluster, cluster
programming, and electronic messages received by
the cluster from the Controller Antilock Brake (CAB)
over the Chrysler Collision Detection (CCD) data bus.
The brake indicator Light Emitting Diode (LED)
receives battery current on the instrument cluster
electronic circuit board through the fused ignition
switch output (st-run) circuit whenever the ignition
switch is in the On or Start positions; therefore, the
LED will always be off when the ignition switch is in
any position except On or Start. The LED only illu-
minates when it is provided a path to ground by the
instrument cluster transistor. The instrument cluster
will turn on the brake indicator for the following rea-
sons:
²Bulb Test- Each time the ignition switch is
turned to the On position the brake indicator is illu-
minated by the instrument cluster for about four sec-
onds as a bulb test.
²Park Brake-On- If the park brake is applied
or not fully released with the ignition switch in the
On position, the brake indicator is illuminated solid.
The brake indicator will blink on and off repeatedly
when the park brake is applied or not fully released
and the ignition switch is in the On position if a
vehicle with an automatic transmission is not in
Park or Neutral, or if the engine is running on vehi-
cles with a manual transmission.
²Brake Lamp-On Message- Each time the
cluster receives a lamp-on message from the CAB,
the brake indicator will be illuminated. The indicator
remains illuminated until the cluster receives a
lamp-off message from the CAB, or until the ignition
switch is turned to the Off position, whichever occurs
first.
²Actuator Test- Each time the instrument clus-
ter is put through the actuator test, the brake indi-
cator will be turned on during the bulb check portion
of the test to confirm the functionality of the LED
and the cluster control circuitry.
The park brake switch on the park brake pedal
mechanism provides a hard wired ground input to
the instrument cluster circuitry through the park
brake switch sense circuit whenever the park brake
is applied or not fully released. The CAB continually
monitors the brake pressure switch on the brake
combination valve to determine if the pressures in
the two halves of the split brake hydraulic system
are unequal. The CAB then sends the proper lamp-on
or lamp-off messages to the instrument cluster. If the
CAB sends a lamp-on message after the bulb test, it
indicates that the CAB has detected a brake hydrau-
lic system malfunction and/or that the ABS system
has become inoperative. The CAB will store a Diag-
nostic Trouble Code (DTC) for any malfunction itdetects. The park brake switch input to the instru-
ment cluster can be diagnosed using conventional
diagnostic tools and methods. For proper diagnosis of
the antilock brake system, the CAB, the CCD data
bus, or the message inputs to the instrument cluster
that control the brake indicator, a DRBIIItscan tool
is required. Refer to the appropriate diagnostic infor-
mation.
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The diagnosis found here addresses an inoperative
brake indicator condition. If the brake indicator
comes on or stays on with the ignition switch in the
On position and the park brake released, or comes on
while driving, the brake system must be diagnosed
and repaired prior to performing the following tests.
(Refer to 5 - BRAKES - DIAGNOSIS AND TEST-
ING). If no brake system problem is found, the fol-
lowing procedure will help locate a faulty park brake
switch or park brake switch sense circuit. Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector for the park brake switch from the switch
terminal. With the park brake released, check for
continuity between the park brake switch terminal
and a good ground. There should be no continuity. If
OK, go to Step 2. If not OK, adjust or replace the
faulty park brake switch.
(2) Remove the instrument cluster from the instru-
ment panel. With the park brake switch still discon-
nected, check for continuity between the park brake
switch sense circuit cavity of the instrument panel
wire harness connector for the park brake switch and
a good ground. There should be no continuity. If OK,
go to Step 3. If not OK, repair the shorted park
8J - 16 INSTRUMENT CLUSTERBR/BE
BRAKE/PARK BRAKE INDICATOR (Continued)
Page 501 of 2255
high beam indicator. If no headlamp system problems
are found, the following procedure will help locate a
short or open in the high beam indicator circuit.
Refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INDICATOR DOES NOT ILLUMINATE WITH HIGH BEAMS
SELECTED
(1) Check the fused B(+) fuse (Fuse 14 - 10
ampere) in the Junction Block (JB). If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
(Fuse 14 - 10 ampere) in the JB. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit between
the JB and the Power Distribution Center (PDC) as
required.
(3) Be certain that the headlamp high beams are
selected with the headlamp beam select switch by
turning the headlamp switch to the On position, pull-
ing the multi-function switch stalk toward the steer-
ing wheel, then inspecting the headlamps at the
front of the vehicle. Once the headlamp high beams
are selected, turn the headlamp switch to the Off
position. Disconnect and isolate the battery negative
cable. Remove the instrument cluster from the
instrument panel. Reconnect the battery negative
cable. Check for battery voltage at the fused B(+) cir-
cuit cavity of the instrument panel wire harness con-
nector (Connector C1) for the instrument cluster. If
OK, go to Step 4. If not OK, repair the open fused
B(+) circuit between the instrument cluster and the
JB as required.
(4) Disconnect and isolate the battery negative
cable. Check for continuity between the high beam
indicator driver circuit cavity of the instrument panel
wire harness connector (Connector C2) for the instru-ment cluster and a good ground. There should be
continuity. If OK, replace the faulty headlamp high
beam indicator bulb and bulb holder unit. If not OK,
repair the open high beam indicator driver circuit
between the instrument cluster and the headlamp
beam select (multi-function) switch as required.
INDICATOR STAYS ILLUMINATED WITH HIGH BEAMS NOT
SELECTED
(1) Be certain that the headlamp low beams are
selected with the headlamp beam select switch by
turning the headlamp switch to the On position, pull-
ing the multi-function switch stalk toward the steer-
ing wheel, then inspecting the headlamps at the
front of the vehicle. Once the headlamp low beams
are selected, turn the headlamp switch to the Off
position. Disconnect and isolate the battery negative
cable. Remove the instrument cluster from the
instrument panel. Check for continuity between the
high beam indicator driver circuit cavity of the
instrument panel wire harness connector (Connector
C2) for the instrument cluster and a good ground.
There should be no continuity. If OK, replace the
faulty instrument cluster. If not OK, repair the
shorted high beam indicator driver circuit between
the instrument cluster and the headlamp beam select
(multi-function) switch as required.
LOW FUEL INDICATOR
DESCRIPTION
A low fuel indicator is standard equipment on all
instrument clusters. The low fuel indicator is located
near the lower edge of the instrument cluster overlay,
to the right of center. The low fuel indicator consists
of a stenciled cutout of the International Control and
Display Symbol icon for ªFuelº in the opaque layer of
the instrument cluster overlay. The dark outer layer
of the overlay prevents the indicator from being
clearly visible when it is not illuminated. An amber
lens behind the cutout in the opaque layer of the
overlay causes the icon to appear in amber through
the translucent outer layer of the overlay when the
indicator is illuminated from behind by a Light Emit-
ting Diode (LED) soldered onto the instrument clus-
ter electronic circuit board. The low fuel indicator is
serviced as a unit with the instrument cluster.
OPERATION
The low fuel indicator gives an indication to the
vehicle operator when the level of fuel in the fuel
tank becomes low. This indicator is controlled by a
transistor on the instrument cluster circuit board
based upon cluster programming and electronic mes-
sages received by the cluster from the Powertrain
Control Module (PCM) over the Chrysler Collision
8J - 22 INSTRUMENT CLUSTERBR/BE
HIGH BEAM INDICATOR (Continued)
Page 508 of 2255
disconnect mechanism, (Refer to 3 - DIFFERENTIAL
& DRIVELINE/FRONT AXLE/AXLE VACUUM
MOTOR - OPERATION). The four-wheel drive switch
input to the instrument cluster circuitry can be diag-
nosed using conventional diagnostic tools and meth-
ods.
DIAGNOSIS AND TESTING - FOUR-WHEEL
DRIVE INDICATOR
The diagnosis found here addresses an inoperative
four-wheel drive indicator condition. If the problem
being diagnosed is related to indicator accuracy, be
certain to confirm that the problem is with the indi-
cator and not with a damaged or inoperative front
axle disconnect mechanism. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/FRONT AXLE/AXLE VACUUM
MOTOR - DIAGNOSIS AND TESTING). If no front
axle disconnect problem is found, the following proce-
dure will help locate a short or open in the four-
wheel drive switch input to the instrument cluster.
Refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INDICATOR DOES NOT ILLUMINATE WITH FOUR-WHEEL
DRIVE MODE SELECTED
(1) Disconnect and isolate the battery negative
cable. Disconnect the engine wire harness connector
for the four-wheel drive switch from the switch con-
nector receptacle. Check for continuity between the
ground circuit cavity of the engine wire harness con-
nector for the four-wheel drive switch and a good
ground. There should be continuity. If OK, go to Step
2. If not OK, repair the open ground circuit to ground
(G100) as required.
(2) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Install a jumper
wire between the 4WD switch sense circuit cavity ofthe engine wire harness connector for the four-wheel
drive switch and a good ground. The four-wheel drive
indicator should light. If OK, replace the faulty four-
wheel drive switch. If not OK, go to Step 3.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the instrument cluster from the instrument
panel. Check for continuity between the 4WD switch
sense circuit cavities of the instrument panel wire
harness connector (Connector C2) for the instrument
cluster and the engine wire harness connector for the
four-wheel drive switch. There should be continuity.
If OK, replace the faulty instrument cluster. If not
OK, repair the open 4WD switch sense circuit
between the instrument cluster and the four-wheel
drive switch as required.
INDICATOR STAYS ILLUMINATED WITH FOUR-WHEEL DRIVE
MODE NOT SELECTED
(1) Disconnect and isolate the battery negative
cable. Disconnect the engine wire harness connector
for the four-wheel drive switch from the switch con-
nector receptacle. Check for continuity between the
ground circuit terminal and the 4WD switch sense
circuit terminal in the four-wheel drive switch con-
nector receptacle. There should be no continuity. If
OK, repair the shorted 4WD switch sense circuit
between the four-wheel drive switch and the instru-
ment cluster as required. If not OK, replace the
faulty four-wheel drive switch.
SPEEDOMETER
DESCRIPTION
A speedometer is standard equipment on all instru-
ment clusters. The speedometer is located just to the
right of the tachometer near the center of the instru-
ment cluster. The speedometer consists of a movable
gauge needle or pointer controlled by the instrument
cluster circuitry and a fixed 210 degree primary scale
on the gauge dial face that reads left-to-right either
from 0 to 120 mph, or from 0 to 200 km/h, depending
upon the market for which the vehicle is manufac-
tured. Each version also has a secondary inner scale
on the gauge dial face that provides the equivalent
opposite units from the primary scale. Text appearing
on the cluster overlay just below the hub of the
speedometer needle abbreviates the unit of measure
for the primary scale in all upper case letters (i.e.:
MPH or KM/H), followed by the unit of measure for
the secondary scale in all lower case letters (i.e.: mph
or km/h). The speedometer graphics are white (pri-
mary scale) and red (secondary scale) against a black
field, making them clearly visible within the instru-
ment cluster in daylight. When illuminated from
behind by the panel lamps dimmer controlled cluster
BR/BEINSTRUMENT CLUSTER 8J - 29
SHIFT INDICATOR (TRANSFER CASE) (Continued)
Page 511 of 2255
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn signal indicators are standard equipment
on all instrument clusters. The turn signal indicators
are located near the upper edge of the instrument
cluster overlay, between the speedometer and the
tachometer. Each turn signal indicator consists of a
stenciled cutout of the International Control and Dis-
play Symbol icon for ªTurn Warningº in the opaque
layer of the instrument cluster overlay. The dark
outer layer of the overlay prevents these icons from
being clearly visible when their lamps are not illumi-
nated. The icons appear in green through the trans-
lucent outer layer of the overlay when the indicator
is illuminated from behind by a replaceable incandes-
cent bulb and bulb holder unit located on the instru-
ment cluster electronic circuit board. The turn signal
indicators are serviced as a unit with the instrument
cluster.
OPERATION
The turn signal indicators give an indication to the
vehicle operator that the turn signal (left or right
indicator flashing) or hazard warning (both left and
right indicators flashing) have been selected. These
indicators are controlled by two individual hard
wired inputs to the instrument cluster electronic cir-
cuit board. The turn signal indicator bulbs are
grounded on the instrument cluster electronic circuit
board at all times. The turn signal indicator bulbs
only illuminate when they are provided with battery
current by the turn signal and hazard warning
switch circuitry of the left multi-function switch on
the steering column through separate left and right
turn signal inputs to the instrument cluster; there-
fore, these indicators can be illuminated, regardless
of the ignition switch position.
The turn signal indicators are connected in series
between ground and the output of the turn signal
and hazard warning switch circuitry, but in parallel
with the other turn signal circuits. This arrangement
allows the turn signal indicators to remain functional
regardless of the condition of the other circuits in the
turn signal and hazard warning system. For more
information on the turn signal and hazard warning
system, (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR - OPERATION - TURN SIGNAL &
HAZARD WARNING SYSTEM). The turn signal
indicators can be diagnosed using conventional diag-
nostic tools and methods.
DIAGNOSIS AND TESTING - TURN SIGNAL
INDICATOR
The diagnosis found here addresses an inoperative
turn signal indicator lamp condition. If the problem
being diagnosed is related to inoperative turn signals
or hazard warning lamps, be certain to repair the
turn signal and hazard warning system before
attempting to diagnose or repair the turn signal indi-
cators. If no turn signal or hazard warning system
problems are found, the following procedure will help
locate a short or open in the left or right turn signal
indicator circuit. Refer to the appropriate wiring
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce-
dures, details of wire harness routing and retention,
connector pin-out information and location views for
the various wire harness connectors, splices and
grounds.
(1) Disconnect and isolate the battery negative
cable. Remove the instrument cluster.
(2) Connect the battery negative cable. Activate
the hazard warning system by moving the hazard
warning switch button to the On position. Check for
battery voltage at the inoperative (right or left) turn
signal circuit cavity of the instrument panel wire
harness connector (Connector C2) for the instrument
cluster. There should be a switching (on and off) bat-
tery voltage signal. If OK, replace the faulty turn sig-
nal indicator bulb. If not OK, repair the open (right
or left) turn signal circuit to the left multi-function
switch as required.
UPSHIFT INDICATOR
DESCRIPTION
An upshift indicator is standard equipment on all
instrument clusters. However, on vehicles not
equipped with a manual transmission, this indicator
is disabled. The upshift indicator is located near the
fuel gauge in the instrument cluster overlay, to the
left of center. The upshift indicator consists of an
upward pointed arrow icon that is a stenciled cutout
in the opaque layer of the instrument cluster overlay.
The dark outer layer of the overlay prevents the indi-
cator from being clearly visible when it is not illumi-
nated. An amber lens behind the cutout in the
opaque layer of the overlay causes the icon to appear
in amber through the translucent outer layer of the
overlay when the indicator is illuminated from
behind by a replaceable incandescent bulb and bulb
holder unit located on the instrument cluster elec-
tronic circuit board. The upshift indicator is serviced
as a unit with the instrument cluster.
8J - 32 INSTRUMENT CLUSTERBR/BE
Page 514 of 2255
WASHER FLUID INDICATOR
DESCRIPTION
A washer fluid indicator is standard equipment on
all instrument clusters. The washer fluid indicator is
located near the lower edge of the instrument cluster
overlay, to the right of center. The washer fluid indi-
cator consists of a stenciled cutout of the words
ªLOW WASHERº in the opaque layer of the instru-
ment cluster overlay. The dark outer layer of the
overlay prevents the indicator from being clearly vis-
ible when it is not illuminated. An amber lens behind
the cutout in the opaque layer of the overlay causes
the ªLOW WASHERº text to appear in amber
through the translucent outer layer of the overlay
when it is illuminated from behind by a Light Emit-
ting Diode (LED) soldered onto the instrument clus-
ter electronic circuit board. The washer fluid
indicator is serviced as a unit with the instrument
cluster.
OPERATION
The washer fluid indicator gives an indication to
the vehicle operator when the fluid level in the
washer fluid reservoir is low. This indicator is con-
trolled by a transistor on the instrument cluster elec-
tronic circuit board based upon cluster programming
and a hard wired washer fluid level switch input to
the cluster. The washer fluid indicator Light Emit-
ting Diode (LED) receives battery current on the
instrument cluster electronic circuit board through
the fused ignition switch output (st-run) circuit
whenever the ignition switch is in the On or Start
positions; therefore, the indicator will always be off
when the ignition switch is in any position except On
or Start. The LED only illuminates when it is pro-
vided a path to ground by the instrument cluster
transistor. The instrument cluster will turn on the
washer fluid indicator for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the indicator is illuminated
for about two seconds as a bulb test.
²Washer Fluid Level Switch Input- Immedi-
ately after the bulb test, if the cluster senses ground
on the washer fluid switch sense circuit for more
than about thirty seconds, it turns on the washer
fluid indicator. Any time after the bulb test, the clus-
ter must sense ground on the washer fluid switch
sense circuit for more than about sixty seconds before
it turns on the indicator. Once illuminated, the indi-
cator will remain illuminated until the ignition
switch is cycled and the cluster senses an open cir-
cuit on the low washer fluid sense input. This strat-
egy is intended to reduce the effect that fluid
sloshing within the washer reservoir can have on
reliable indicator operation.²Actuator Test- Each time the cluster is put
through the actuator test, the indicator will be
turned on during the bulb check portion of the test to
confirm the functionality of the LED and the cluster
control circuitry.
The washer fluid level switch is connected in series
between ground and the washer fluid switch sense
input to the instrument cluster. For more informa-
tion on the washer fluid level switch,(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WASHER FLUID
LEVEL SWITCH - OPERATION). For further diag-
nosis of the washer fluid indicator or the instrument
cluster circuitry that controls the indicator, (Refer to
8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAG-
NOSIS AND TESTING). The washer fluid level
switch input to the cluster can be diagnosed using
conventional diagnostic tools and methods.
DIAGNOSIS AND TESTING - WASHER FLUID
INDICATOR
The diagnosis found here addresses an inoperative
washer fluid indicator condition. If the problem being
diagnosed is related to indicator accuracy, be certain
to confirm that the problem is with the indicator or
washer fluid level switch input and not with a dam-
aged or empty washer fluid reservoir, or inoperative
instrument cluster indicator control circuitry. Inspect
the washer fluid reservoir for proper fluid level and
signs of damage or distortion that could affect
washer fluid level switch performance and perform
the instrument cluster actuator test before you pro-
ceed with the following diagnosis. If no washer fluid
reservoir or instrument cluster control circuitry prob-
lem is found, the following procedure will help to
locate a short or open in the washer fluid switch
sense circuit. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
details of wire harness routing and retention, connec-
tor pin-out information and location views for the
various wire harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
BR/BEINSTRUMENT CLUSTER 8J - 35
Page 516 of 2255
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 33
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM.....................2
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM.....................2
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEM.............3
SPECIFICATIONS
EXTERIOR LAMPS.....................4
SPECIAL TOOLS
HEADLAMP ALIGNMENT................4
BRAKE LAMP SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH.............................5
REMOVAL.............................5
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP
REMOVAL.............................6
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL.............................6
INSTALLATION..........................6
CLEARANCE LAMP
REMOVAL.............................7
INSTALLATION..........................7
COMBINATION FLASHER
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................8
INSTALLATION..........................9
DAYTIME RUNNING LAMP MODULE
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................9
INSTALLATION..........................9FOG LAMP
DIAGNOSIS AND TESTING - FOG LAMP.....10
REMOVAL.............................11
INSTALLATION.........................11
FOG LAMP UNIT
REMOVAL.............................12
INSTALLATION.........................12
ADJUSTMENTS........................13
HEADLAMP
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING - HEADLAMP.....14
REMOVAL.............................16
INSTALLATION.........................16
HEADLAMP RELAY
DESCRIPTION.........................17
OPERATION...........................17
DIAGNOSIS AND TESTING - HEADLAMP
RELAY..............................17
REMOVAL.............................18
INSTALLATION.........................18
HEADLAMP SWITCH
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH............................19
REMOVAL.............................19
INSTALLATION.........................20
HEADLAMP UNIT
REMOVAL.............................20
INSTALLATION.........................21
ADJUSTMENTS........................21
LICENSE PLATE LAMP
REMOVAL.............................22
INSTALLATION.........................22
LICENSE PLATE LAMP UNIT
REMOVAL.............................22
BR/BELAMPS 8L - 1
Page 517 of 2255
INSTALLATION.........................22
MARKER LAMP
REMOVAL.............................23
INSTALLATION.........................23
MULTI-FUNCTION SWITCH
DESCRIPTION.........................23
OPERATION...........................24
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................25
REMOVAL.............................27
INSTALLATION.........................28
OUTBOARD IDENTIFICATION LAMP
REMOVAL.............................28
INSTALLATION.........................29
PARK/TURN SIGNAL LAMP
REMOVAL.............................29
INSTALLATION.........................29
PARK/TURN SIGNAL LAMP UNIT
REMOVAL.............................29INSTALLATION.........................29
TAIL LAMP
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................30
TAIL LAMP UNIT
REMOVAL.............................30
INSTALLATION.........................30
TURN SIGNAL CANCEL CAM
DESCRIPTION.........................31
OPERATION...........................31
UNDERHOOD LAMP
REMOVAL.............................31
INSTALLATION.........................32
UNDERHOOD LAMP UNIT
REMOVAL.............................32
INSTALLATION.........................32
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM
A turn signal and hazard warning system is stan-
dard factory-installed safety equipment on this
model. The turn signal and hazard warning system
includes the following major components, which are
described in further detail elsewhere in this service
information:
²Combination Flasher- The electronic combi-
nation flasher is installed in the Junction Block (JB),
which is located behind the fuse access panel on the
left outboard end of the instrument panel.
²Hazard Warning Switch- The hazard warning
switch is integral to the multi-function switch on the
left side of the steering column. The hazard warning
switch button protrudes from a dedicated opening in
the shroud on the top of the steering column, just
below the steering wheel.
²Turn Signal Cancel Cam- The turn signal
cancel cam is integral to the clockspring, which is
located beneath the steering column shrouds at the
top of the steering column, just below the steering
wheel.
²Turn Signal Indicators- The two turn signal
indicators, one right and one left, are integral to the
ElectroMechanical Instrument Cluster (EMIC)
located in the instrument panel.
²Turn Signal Lamps- The front turn signal
lamps are integral to the lower front outboard ends
of the headlamp modules, located just outboard of the
two sides of the radiator grille opening. The rear
turn signal lamps are integral to the taillamp mod-
ules located on either side of the vehicle. For pickup
models the taillamp modules are secured to the rear
of the quarter panels at each side of the tailgateopening. For cab and chassis models the taillamp
modules are secured by a stamped steel bracket on
the outboard side of each frame rail near the rear of
the vehicle.
²Turn Signal Switch- The turn signal switch is
integral to the multi-function switch on the left side
of the steering column. The multi-function switch
control stalk that actuates the turn signal switch
protrudes from a dedicated opening in the steering
column shrouds on the left side of the column, just
below the steering wheel.
Hard wired circuitry connects the turn signal and
hazard warning system components to each other
through the electrical system of the vehicle. These
hard wired circuits are integral to several wire har-
nesses, which are routed throughout the vehicle and
retained by many different methods. These circuits
may be connected to each other, to the vehicle elec-
trical system and to the turn signal and hazard
warning system components through the use of a
combination of soldered splices, splice block connec-
tors and many different types of wire harness termi-
nal connectors and insulators. Refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM
The turn signal system operates on battery current
received on a fused ignition switch output (run-acc)
circuit so that the turn signals will only operate with
the ignition switch in the On or Accessory positions.
The hazard warning system operates on non-
8L - 2 LAMPS/LIGHTING - EXTERIORBR/BE