automatic transmission DODGE RAM 2002 Service Repair Manual

LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 318).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).
Turning the adjusting screw counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 319).
Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt-
tle valve.
Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever cam
touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 316 Manual Lever Shaft Seal
1 - 15/16©© SOCKET
2 - SEAL
Fig. 317 Accumulator Piston Components
1 - INNER SPRING
2 - ACCUMULATOR PISTON
3 - OUTER SPRING
4 - SEAL RINGS
Fig. 318 Line Pressure Adjustment
1 - WRENCH
2 - 1±5/16 INCH
Fig. 319 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
BR/BEAUTOMATIC TRANSMISSION - 47RE 21 - 429
VALVE BODY (Continued)

exception being when the road surface is covered by
ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
A front axle disconnect system is used to achieve
two-wheel drive mode. The axle disconnect vacuum
motor is actuated by a vacuum switch on the transfer
case. The switch is operated by the transfer case
range rod.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The synchronizer components allow the transfer
case to be shifted between the 2H and 4H operating
ranges while the vehicle is in motion. The vehicle
must have the transmission placed in NEUTRAL, or
the clutch depressed in the case of a manual trans-
mission, and be moving less than 2-3 MPH when
shifting into the 4L operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
BR/BETRANSFER CASE - NV241LD 21 - 431
TRANSFER CASE - NV241LD (Continued)

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 96).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 97).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
Plug, Extension - C-293-3
Tool Set - L-4518
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 96 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 460 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
21 - 468 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8155, remove bushing from
extension housing (Fig. 97).
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8156, drive bushing into hous-
ing until installer seats against case (Fig. 98).
(4) Using Installer 8154, install seal in extension
housing (Fig. 99).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
Fig. 97 Extension Housing Bushing Removal
1 - REMOVER 8155
2 - EXTENSION HOUSING BUSHING
Fig. 98 Extension Housing Bushing Installation
1 - EXTENSION HOUSING BUSHING
2 - INSTALLER 8156
Fig. 99 Install Extension Housing Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8154
BR/BETRANSFER CASE - NV241HD 21 - 497

INSTRUMENT PANEL SYSTEM
TABLE OF CONTENTS
page page
INSTRUMENT PANEL SYSTEM
DESCRIPTION........................105
OPERATION..........................106
ASH RECEIVER
REMOVAL............................107
INSTALLATION........................107
CLUSTER BEZEL
REMOVAL............................108
INSTALLATION........................108
CUBBY BIN
REMOVAL............................108
INSTALLATION........................109
CUP HOLDER
REMOVAL............................109
INSTALLATION........................110
GLOVE BOX
REMOVAL
REMOVAL..........................110
DISASSEMBLY - GLOVE BOX...........110
ASSEMBLY - GLOVE BOX................111INSTALLATION........................111
GLOVE BOX LATCH STRIKER
REMOVAL............................111
INSTALLATION........................112
GLOVE BOX OPENING UPPER TRIM
REMOVAL............................112
INSTALLATION........................112
INSTRUMENT PANEL TOP COVER
REMOVAL............................113
INSTALLATION........................113
STEERING COLUMN OPENING COVER
REMOVAL............................113
INSTALLATION........................114
STORAGE BIN
REMOVAL............................114
INSTALLATION........................114
INSTRUMENT PANEL ASSEMBLY
REMOVAL............................115
INSTALLATION........................117
INSTRUMENT PANEL SYSTEM
DESCRIPTION
The instrument panel is located at the front of the
passenger compartment. This instrument panel is
molded from a blend of various plastics that are
mechanically attached to the vehicle. Colors are
molded into the plastic components to minimize
appearance degradation from scratches or abrasions.
The panel components are internally ribbed and riv-
eted to steel reinforcements for additional structural
integrity and dimensional stability. The instrument
panel surface components are designed to deform
upon impact without breaking. This type of construc-
tion provides improved energy absorption which, in
conjunction with the dual airbags and seat belts,
helps to improve occupant protection.
The top of the instrument panel is secured to the
top of the dash panel near the base of the windshield
using screws. An end bracket integral to each end of
the instrument panel structure is secured to each
cowl side inner panel with a screw. A stamped metal
bracket supports the center of the instrument panel
by securing it to the top of the floor panel transmis-
sion tunnel below the instrument panel with screws.
The instrument cluster, radio, heater-air conditioner
control, passenger airbag, glove box, electrical junc-tion block, Central Timer Module (CTM), accessory
switches, ash receiver, cigar lighter, accessory power
outlet, park brake release handle, inside hood release
handle, as well as numerous other components are
secured to and supported by this unit.
The instrument panel for this vehicle includes the
following major features:
²Cluster Bezel- This molded plastic bezel is
secured with snap clips to the instrument panel sup-
porting structure. It trims out the edges of the head-
lamp switch, instrument cluster, radio, heater-air
conditioner controls, passenger airbag on-off switch,
and the heated seat switches on vehicles so equipped.
On vehicles without the heated seat option, a small
storage cubby bin is provided in the cluster bezel.
This bezel also incorporates three completely adjust-
able panel outlets for the climate control system, and
fills the opening between the instrument cluster and
the top of the steering column where it passes
through the instrument panel.
²Cup Holder/Storage Bin- Vehicles equipped
with an automatic transmission feature a latching
fold-down, adjustable cup holder located on the lower
instrument panel between the glove box and the ash
receiver. Vehicles equipped with a manual transmis-
sion have a lighted storage bin on the instrument
panel in place of the cup holder.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 105

²Glove Box- The hinged bin-type glove box in
the passenger side of the instrument panel features a
recessed paddle-operated latch handle. Three molded
hook formations on the lower edge of the glove box
door are engaged with and pivot on three hinge pins
integral to the lower edge of the instrument panel
support structure. The glove box door also serves as
the passenger side knee blocker. A honeycomb struc-
ture between the inner and outer glove box door pan-
els helps to absorb the impact load and distribute it
to the instrument panel structure.
²Steering Column Opening Cover- The steer-
ing column opening cover serves as the driver side
knee blocker. This molded plastic cover has an inte-
gral ribbed plastic liner concealed behind it, for
increased strength and integrity. The steering column
opening cover transfers impact loads to the instru-
ment panel structural support.
²Top Cover- The instrument panel top cover or
base trim is the molded, grained, and color impreg-
nated plastic outer skin of the instrument panel
structural support.
Hard wired circuitry connects the electrical compo-
nents on the instrument panel to each other through
the electrical system of the vehicle. These hard wired
circuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the instrument panel components through the
use of a combination of soldered splices, splice block
connectors and many different types of wire harness
terminal connectors and insulators. Refer to the
appropriate wiring information. The wiring informa-
tion includes complete circuit diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices, and grounds.
OPERATION
The instrument panel serves as the command cen-
ter of the vehicle, which necessarily makes it a very
complex unit. The instrument panel is designed to
house the controls and monitors for standard and
optional powertrains, climate control systems, audio
systems, safety systems, and many other comfort or
convenience items. When the components of the
instrument panel structural support are properly
assembled and secured in the vehicle they provide
superior instrument panel stiffness and integrity to
help reduce buzzes, squeaks, and rattles. This type of
construction also provides improved energy absorp-
tion which, in conjunction with the dual airbags and
seat belts, helps to improve occupant protection.The instrument panel is also designed so that all of
the various controls can be safely reached and the
monitors can be easily viewed by the vehicle operator
when driving, while still allowing relative ease of
access to each of these items for service. Modular
instrument panel construction allows all of the
gauges and controls to be serviced from the front of
the panel. In addition, most of the instrument panel
electrical components can be accessed without com-
plete instrument panel removal. However, if neces-
sary, the instrument panel can be removed from the
vehicle as an assembly.
The steering column opening cover with its inte-
gral knee blocker located on the driver side of the
instrument panel works in conjunction with the air-
bag system in a frontal vehicle impact to keep the
driver properly positioned for an airbag deployment.
In addition, removal of this component provides
access to the steering column mounts, the steering
column wiring, the Junction Block (JB) (removal of a
snap-fit fuse access panel on the left end of the
instrument panel allows access to the fuses and cir-
cuit breakers), the Central Timer Module (CTM), the
Infinity speaker filter choke and relay unit, much of
the instrument panel wiring, and the gear selector
indicator cable (automatic transmission).
In a frontal collision, the glove box door on the pas-
senger side of the instrument panel provides the
same function for the front seat passenger as the
knee blocker does for the driver. The glove box door
also incorporates a recessed latch handle. Removal of
the glove box provides access to the passenger airbag,
the glove box lamp and switch, the radio antenna
coaxial cable, the heating and air conditioning vac-
uum harness connector, and additional instrument
panel wiring.
Removal of the instrument panel cluster bezel
allows access to the headlamp switch, instrument
cluster, radio, passenger airbag on-off switch, heated
seat switches (if equipped), and the heating and air
conditioning control. Removal of the instrument clus-
ter allows access to the cluster illumination and indi-
cator bulbs, and more of the instrument panel
wiring. Complete instrument panel removal is
required for service of most components internal to
the heating and air conditioning system housing,
including the heater core and the evaporator.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the components and systems mounted on or
in the instrument panel.
23 - 106 INSTRUMENT PANEL SYSTEMBR/BE
INSTRUMENT PANEL SYSTEM (Continued)

CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is equipped with an automatic
transmission, turn the ignition switch to the Off posi-
tion (not Lock), set the parking brake, and place the
automatic transmission gear selector lever in the
Low position.
(3) If the vehicle is so equipped, set the tilt steer-
ing column in its lowest position.
(4) Using a trim stick or another suitable wide
flat-bladed tool, gently pry around the perimeter of
the cluster bezel to disengage the snap clips from
their receptacles in the instrument panel (Fig. 2).
(5) Remove the cluster bezel from the instrument
panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cluster bezel to the instrument
panel (Fig. 2).
(2) Align the snap clips on the cluster bezel with
the receptacles in the instrument panel.
(3) Press firmly on the cluster bezel over each of
the snap clip locations until each of the snap clips is
fully engaged in its receptacle.
(4) Reconnect the battery negative cable.
CUBBY BIN
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the three screws that secure the cubby
bin to the instrument panel (Fig. 3).
(4) Remove the cubby bin from the instrument
panel.
Fig. 2 Cluster Bezel Remove/Install
1 - CLUSTER BEZEL
23 - 108 INSTRUMENT PANEL SYSTEMBR/BE

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cubby bin to the instrument panel
(Fig. 3).
(2) Install and tighten the three screws that secure
the cubby bin to the instrument panel. Tighten the
screws to 2 N´m (20 in. lbs.).
(3) Install the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
CUP HOLDER
REMOVAL
Vehicles equipped with an automatic transmission
have a lighted fold-down cup holder installed on the
instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Unlatch and fold the cup holder down from the
instrument panel to its open position.
(4) Remove the six screws that secure the cup
holder to the instrument panel (Fig. 4).
(5) Pull the cup holder away from the instrument
panel far enough to access the illumination lamp and
hood unit.
(6) Disengage the illumination lamp and hood
retainer clip from the back of the instrument panel
cup holder unit.
(7) Remove the cup holder unit from the instru-
ment panel.
Fig. 3 Instrument Panel Cubby Bin Remove/Install
1 - SCREW (3)
2 - CUBBY BIN
Fig. 4 Instrument Panel Cup Holder
1 - SCREW
2 - INSTRUMENT PANEL
3 - CUP HOLDER
BR/BEINSTRUMENT PANEL SYSTEM 23 - 109
CUBBY BIN (Continued)

INSTALLATION
Vehicles equipped with an automatic transmission
have a lighted fold-down cup holder installed on the
instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cup holder unit near the instru-
ment panel.
(2) Engage the illumination lamp and hood
retainer clip to the back of the instrument panel cup
holder unit.
(3) Position the cup holder unit onto the instru-
ment panel (Fig. 4).
(4) Install and tighten the six screws that secure
the cup holder to the instrument panel. Tighten the
screws to 2 N´m (20 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
GLOVE BOX
REMOVAL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) While holding the glove box door securely with
one hand, push the center of the glove box bin
towards the front of the vehicle (Fig. 5). Flex the cen-
ter of the glove box bin far enough so that the glove
box stops on each side of the bin will clear the sides
of the instrument panel glove box opening.
(4) Roll the glove box downward until the stop
bumpers are beyond the sides of the instrument
panel glove box opening, then release the bin.
(5) Lift the bottom of the glove box upward to dis-
engage the three glove box hinge hooks from the
three hinge pins on the instrument panel.
DISASSEMBLY - GLOVE BOX
The only serviced component of the glove box is the
glove box bin. If any other component of the glove
box is faulty or damaged, the entire glove box assem-
bly must be replaced.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Remove the two screws that secure each out-
board flange of the glove box bin to the glove box
door (Fig. 6).
(4) Pull the top of the bin away from the top of the
glove box door.
Fig. 5 Glove Box
1 - GLOVE BOX STOPS
2 - GLOVE BOX BIN
3 - GLOVE BOX DOOR
4 - PUSH
23 - 110 INSTRUMENT PANEL SYSTEMBR/BE
CUP HOLDER (Continued)