How much of a hassle is it to change dash panel lights?

[Crunch]

I just finished another long trip, a good part of it over rough roads. When driving at night I noticed that one of the lights behind the oil pressure gauge was out, and the light behind the air/heat/defrost knob had worked loose, but tapping on the dash brought back some light for the knob. Is it something that can be fixed easily, and therefor as needed? Or is it better to wait until several are out and doing them all at once?

 

[EricBu12]

Here is the step by step. I have uploaded the pictures but they are out of sequence but you can see what it is.


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).




Instrument panel removal

1. Disconnect and isolate the negative battery cable.
2. Remove the steering column opening cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - REMOVAL)

STEERING COLUMN OPENING COVER REMOVAL

1. Remove the park brake release handle. (Refer to 5
- BRAKES/PARKING BRAKE/RELEASE -
REMOVAL)

BRAKE HANDLE-RELEASE REMOVAL

1. Disconnect and isolate the battery negative cable.
2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip
that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel.
3. Disengage the park brake release linkage rod end from the park brake mechanism.
4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake
release linkage rod to the lever on the back of the park brake release handle.
5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to
disengage the park brake release linkage rod end from the lever on the back of the park brake release handle.
6. Lift the park brake release handle to access the handle mounting bracket.
7. Using a trim stick (4) or another suitable wide flatbladed
tool, gently pry each of the park brake
release handle (6) mounting bracket latch tabs (5)
away from the retaining notches in the instrument
panel receptacle.
8. With both of the park brake release handle mounting
bracket latches released, slide the handle and
bracket assembly down and out of the instrument
panel receptacle.
5 - 102 BRAKES - BASE - SERVICE INFORMATION DR
INSTALLATION
1. Position the park brake release handle to the
instrument panel.
2. Slide the handle and bracket assembly up into the
instrument panel receptacle until both of the park
brake release handle (6) mounting bracket latches
are engaged with the notches in the instrument
panel receptacle.
3. Lower the park brake release handle and reach
under the driver side outboard end of the instrument
panel to engage the park brake release linkage
rod end with the lever on the back of the park
brake release handle (6).
4. Lift the park brake release handle to access and
snap the plastic retainer clip that secures the park
brake release linkage rod to the lever on the back
of the park brake release handle over the linkage
rod.
5. Reach under the driver side outboard end of the
instrument panel to access and engage the park
brake release linkage rod end to the park brake
mechanism.
6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on
the left cowl side inner panel over the linkage rod.
7. Reconnect the battery negative cable

2. Remove the two screws that secure the bottom of
the steering column opening cover (3) to the instrument
panel.
3. Using a trim stick C-4755 or equivalent, release the
two retainer clips that secure the top of the steering
column opening cover (2) to the instrument panel
and remove the cover.
23 - 170 INSTRUMENT PANEL DR
4. Remove the screws and remove the knee blocker.
INSTALLATION
1. Install the knee blocker (2) and install the screws
(1).
2. Position the steering column opening cover (2) to
the instrument panel and fully engage the two
upper retainer clips to the instrument panel.
3. Install the two screws that secure the steering column
opening cover to the instrument panel.
4. Install the park brake release handle. (Refer to 5 -
BRAKES/PARKING BRAKE/RELEASE -
INSTALLATION)

CONTINUE INSTRUMENT PANEL REMOVAL

3. Remove the screws (2) that secure the top of the instrument cluster bezel (1) to the instrument panel.
4. Using a trim stick C-4755 or equivalent, disengage the two retainer clips that secure the top of the instrument
cluster bezel to the instrument panel.
DR INSTRUMENT PANEL 23 - 139
5. Carefully disengage the instrument cluster bezel from the instrument panel opening and remove the bezel.
INSTALLATION
1. Install the instrument cluster bezel onto the instrument panel and fully engage the two retainer clips to the instrument
panel.
2. Install the screws (2) that secure the instrument cluster bezel to the instrument panel.
3. Install the steering column opening cover. (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION)
4. Connect the negative battery cable.
3. Remove the four screws (2) that secure the instrument
cluster (1) to the instrument panel structural
support (3).
4. Pull the instrument cluster rearward far enough to
access and disconnect the three instrument panel
wire harness connectors (2) from the connector
receptacles (1), C1, C3 and C4 from right to left on
the back of the cluster housing.
5. Remove the instrument cluster from the instrument
panel.
DISASSEMBLY
WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact
sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis
or service. This is the only sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.
NOTE: Some of the components for the instrument cluster used in this vehicle are serviced individually. The
serviced components include the incandescent instrument cluster illumination lamp bulbs (including the
integral bulb holders), and the cluster lens, hood and mask unit. Following are the procedures for disassembling
these components from the instrument cluster.
DR INSTRUMENT CLUSTER - SERVICE INFORMATION 8J - 65
CLUSTER BULB
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument cluster from the instrument
panel. (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - REMOVAL).
3. From the back of the instrument cluster (1), turn
the bulb holder counterclockwise about 30 degrees
on the cluster electronic circuit board.
4. Pull the bulb and bulb holder unit straight out from
the keyed opening 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 8 - ELECTRICAL/INSTRUMENT
CLUSTER - REMOVAL).
3. From the back of the instrument cluster, remove
the eight screws (1) around the outer perimeter of
the rear cover (2) that secure the lens, hood, and
mask unit (4) to the cluster housing (3).
4. Remove the lens, hood, and mask unit from the
face of the instrument cluster.
ASSEMBLY
WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact
sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis
or service. This is the only sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.
NOTE: Some of the components for the instrument cluster used in this vehicle are serviced individually. The
serviced components include the incandescent instrument cluster illumination lamp bulbs (including the
integral bulb holders), and the cluster lens, hood and mask unit. Following are the procedures for assembling
these components to the instrument cluster.
CLUSTER BULB
CAUTION: 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.
8J - 66 INSTRUMENT CLUSTER - SERVICE INFORMATION DR
1. Align the bulb and bulb holder unit with the keyed
opening on the back of the cluster electronic circuit
board.
2. Insert the bulb and bulb holder into the cluster
electronic circuit board until the bulb holder is firmly
seated.
3. Rotate the bulb holder clockwise about 30 degrees
to lock it into place.
4. Reinstall the instrument cluster onto the instrument
panel. (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - INSTALLATION).
5. Reconnect the battery negative cable.
CLUSTER LENS, HOOD, AND MASK
1. Position the cluster lens, hood, and mask unit (4)
over the face of the instrument cluster (3). Be certain
that the odometer/trip odometer switch button
is inserted through the proper clearance holes in
the mask and the lens.
2. From the back of the instrument cluster, install and
tighten the eight screws (1) around the outer perimeter
of the rear cover (2) that secure the lens,
hood, and mask unit to the cluster housing. Tighten
the screws to 1 N·m (10 in. lbs. ).
3. Reinstall the instrument cluster onto the instrument
panel. (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - INSTALLATION).
4. Reconnect the battery negative cable.

 

[EricBu12]

Heres a couple more pics of the bezel

 

[Crunch]

Here is the step by step. I have uploaded the pictures but they are out of sequence but you can see what it is.

Ish! I guess I'll be waiting for the rest of them to go out before removing that much of the dash. Sounds like it could take most of the day for me...



Thanks.

 

[blacksheepdiesel]

After reading the above instructions I was not looking forward to replacing my instrument cluster with a used one. A local dealer tech told me it was really not that big a deal. He was right, actually quite simple, much more so than the above instructions make it seem. Can be done in a half hour or so.

Don't be afraid of it.

Godspeed,
Trent

 

[jhenderson]

Remember, the bulbs for the heater controls are different than the inst. cluster. Ask me how I know.

 

[TimothyLong]

I've been in mine twice. Like anything else, the first time is a PITA. The second time I did it in less than 30 min. The reason I had to do it twice was because I didn't have enough bulbs to replace all that had burned out. What I found when I go in there were several that were black at the tip of the light. Kind of like a Christmas light just burns out. Even though they still worked, I did a pre-emptive strike and replaced the one that looked the worst.

 

[Shadrach]

When you go in there change ALL the bulbs. That way you only have to do it once. Shad

 

[rashwor]

I agree with Shad... do all of them at once if you are going in. The bulbs cost less than going back in next week to do another bulb! I had a dealer tech do mine and we did all of them at one time. If I rememeber correctly, the A/C control panel lights are a dealer only item part... . Seems like 11 bulbs in the instrument panel and 3 in the A/C control cluster IIRC.

 

[ScottRoberts]

Does anyone have a part number for the replacement cluster bulbs and where they can be found? I did not see anything listed in the posts above and would like to have them on hand prior to pulling everything apart.



Thanks.

 

[TimothyLong]

I got mine from Mopar Parts Catalog (WholesaleMoparParts.com). Since I got mine, they changed their website around a little and I don't know if they are as easy to find as they were before. If you call them, I'm sure they can help you out. They've been really great any time I've had to call with questions.

 

[rashwor]

mopar4less.com will be glad to help with the part numbers and availability. I have dealt with them and their prices are way better than our local dealers.



If I remember right, the instrument cluster takes 11 bulbs, #194 or # 168. The A/C control assembly backlight takes 3 bulbs and they are a mopar only item (05135537AA).

 

[Blakers]

Which should I buy? the #194 or the #168 ? Is one brighter? Will they interchange?

Thanks.

 

[Blakers]

Anyone tried these:

http://www.amazon.com/dp/B00KVWQHD6...=UTF8&colid=QLK5TL2363AC&coliid=IMM8R42RIHBA8

or

http://www.ebay.com/itm/111365719279?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

 

[wcjp]

I previously found a link from Youtube for Tach repair.



Video for dash gauge removal

 

[Blakers]

Thanks for sharing this YouTube video wcjp. Though it is an 06, it should be similar to the 03. I didn't see how the lights were replaced on the 06 though. Are they similar?

 

[Blakers]

Here's a really good thread over at CumminsForum that pretty much says it all and tells you which LEDs will work in the dash and the HVAC.

http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/183809-led-interior.html