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Home >> Dodge or Ram Truck >> 2001 >> RAM 3500 Van V8-5.9L VIN Z LDC >> Repair and Diagnosis >> Instrument Panel, Gauges and Warning Indicators >> Instrument Cluster / Carrier >> Service and Repair >> Procedures >> Instrument Cluster Disassembly and Assembly

Instrument Cluster Disassembly and Assembly

DISASSEMBLY
Some of the components for the instrument cluster used in this vehicle are serviced individually. The serviced components includes: the incandescent instrument cluster indicator and illumination lamp bulbs (including the integral bulb holders), the cluster lens, hood, and mask unit, and the cluster housing rear cover. The remaining components are serviced only as a part of the cluster housing unit, which includes: the cluster housing, the electronic circuit board unit, the cluster overlay, the gauges, and the odometer/trip odometer reset switch button.

Following are the procedures for disassembling the serviced components from the instrument cluster unit.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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.

Cluster Bulb
This procedure applies to each of the incandescent cluster illumination lamp or indicator bulb and bulb holder units. However, the illumination lamps and the indicators 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 instrument panel. (Refer to INSTRUMENT CLUSTER - REMOVAL).

Fig. 2 Cluster Bulb Remove/Install:




3. Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board (Fig. 2).
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, Hood, And Mask
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument panel. (Refer to INSTRUMENT CLUSTER - REMOVAL).

Fig. 3 Instrument Cluster Components:




3. Remove the eight screws (six from the front and two from the rear) that secure the lens, hood, and mask unit to the cluster housing (Fig. 3).
4. Release the latch at the lower center edge of the cluster lens, hood, and mask unit that secures it to the cluster housing.
5. Gently pull the lens, hood, and mask unit away from the cluster housing.

CAUTION: Do not touch the face of the gauge overlay 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 instrument panel. (Refer to INSTRUMENT CLUSTER - REMOVAL).
3. Remove the five screws that secure the rear cover to the back of the cluster housing (Fig. 3).
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 instrument panel. (Refer to INSTRUMENT CLUSTER - REMOVAL).
3. Remove the lens, hood, and mask unit from the cluster housing. Refer to CLUSTER LENS, HOOD, AND MASK
4. Remove the rear cover from the cluster housing. Refer to CLUSTER HOUSING REAR COVER.

ASSEMBLY

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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.

Cluster Bulb
This procedure applies to each of the incandescent cluster illumination lamp or indicator bulb and bulb holder units. However, the illumination lamps and the indicators 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 electronic 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. 2).
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 INSTRUMENT CLUSTER - INSTALLATION).
4. Reconnect the battery negative cable.

Cluster Lens, Hood, And Mask

CAUTION: Do not touch the face of the gauge overlay or the back of the cluster lens with your finger. It will leave a permanent finger print.

1. Align the cluster lens, hood, and mask unit with the cluster housing. Be certain that the odometer/trip odometer switch button is installed through the clearance hole in the lens (Fig. 3).
2. Using hand pressure, press firmly and evenly on the lens, hood, and mask unit until it is fully seated on the cluster housing. Be certain that the latch at the lower center edge of the cluster lens, hood, and mask unit that secures it to the cluster housing is fully engaged.
3. Install and tighten the eight screws (six from the front two from the rear) that secure the lens, mask, and hood unit to the cluster housing. Tighten the screws to 2 Nm (17 in. lbs.).
4. Reinstall the instrument cluster onto the instrument panel. (Refer to INSTRUMENT CLUSTER - INSTALLATION).
5. Reconnect the battery negative cable.

Cluster Housing Rear Cover
1. Position the rear cover onto the back of the cluster housing (Fig. 3).
2. Install and tighten the five screws that secure the rear cover to the back of the cluster housing. Tighten the screws to 2 Nm (17 in. lbs.).
3. Reinstall the instrument cluster onto the instrument panel. (Refer to INSTRUMENT CLUSTER - INSTALLATION).
4. Reconnect the battery negative cable.

Cluster Housing
1. Assemble the rear cover onto the cluster housing. Refer to CLUSTER HOUSING REAR COVER.
2. Assemble the lens, hood, and mask unit onto the cluster housing. Refer to CLUSTER LENS, HOOD, AND MASK.
3. Reinstall the instrument cluster onto the instrument panel. (Refer to INSTRUMENT CLUSTER - INSTALLATION).
4. Reconnect the battery negative cable.
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