Chrysler Caravan/Voyager/Town and Country 1996-1999

Instrument Panel and Pad

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8

  1. Disconnect the negative battery cable.
  2.  


CAUTION
The vehicles covered by this guide are all equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Chassis Electrical .

  1. Disable the air bag system.
  2.  
  3. Remove the screws that hold the lower instrument panel console to the floor bracket and instrument panel.
  4.  
  5. Move the console rearward from around the instrument panel supports.
  6.  
  7. Remove the lower instrument panel console.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the lower instrument panel console from the vehicle



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Fig. Fig. 2: Remove the lower heat duct from the instrument panel support



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Fig. Fig. 3: Remove the lower instrument panel supports from the vehicle

  1. Remove the screw that secures the lower heat duct to the instrument panel support.
  2.  
  3. Remove the heat duct from the vehicle.
  4.  
  5. Remove the bolts securing the lower supports to the instrument panel frame and floor.
  6.  
  7. Remove the right instrument panel end cover by performing the following;
    1. Open the passenger side door.
    2.  
    3. Disengage the retaining clips securing the cover to the instrument panel.
    4.  
    5. Remove the foam pad covering the A/C inlet projection of the end cover, if equipped.

      Click image to see an enlarged view

      Fig. Fig. 4: Remove the left instrument panel end cover

    6.  

  8.  
  9. Remove the left instrument panel end cover by performing the following;
    1. Open the driver side door.
    2.  
    3. Remove screws holding the parking brake release handle to the instrument panel.
    4.  
    5. Remove the screws that hold the bottom of the lower steering column cover to the instrument panel.
    6.  
    7. Remove the screw that holds the right side of the lower steering column cover to the instrument panel.
    8.  
    9. Disengage the parking brake release cable case from the groove on the end of the parking brake release handle, then disengage the cable end pivot from the slot on the release handle.
    10.  
    11. Disengage the retaining clips securing the end cover to the instrument panel.
    12.  

  10.  
  11. Disengage the wiring harness connector from the passenger air bag module.
  12.  
  13. Disengage the hidden retaining clips that secure the door sill plate from the door sill. Remove the left and right side door sill plates from the vehicle.
  14.  
  15. Disengage the hidden retaining clips that secure the interior cowl trim from the cowl panel. Remove the left and right side interior cowl trim from the vehicle.
  16.  
  17. Remove the A-pillar trim covers.
  18.  



Click image to see an enlarged view

Fig. Fig. 5: Glove box assembly exploded view

  1. Remove the glove box.
  2.  
  3. Unplug the antenna lead connector from behind the glove box.
  4.  
  5. Remove the knee blocker reinforcement panel from under the steering column.
  6.  



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Fig. Fig. 6: Junction block and body control module connectors

  1. Unplug the lower two, 40-pin wiring harness connectors from the main junction block near the left side cowl panel.
  2.  
  3. Unplug the instrument panel wiring harness connector from the bottom of the body control module.
  4.  
  5. Unplug the two, 40-pin wiring harness connectors from the right of the steering column.
  6.  



Click image to see an enlarged view

Fig. Fig. 7: Remove the clinch bolt joining the upper-to-lower steering column shafts

  1. Remove the clinch bolt securing the upper steering column shaft to the lower steering column shaft. Separate the upper and lower shaft.
  2.  
  3. Remove the nuts securing the instrument panel frame to the metal brake pedal support on each side of the steering column.
  4.  
  5. If equipped with a mechanical transmission range indicator, perform the following;
    1. Remove the indicator cable loop.
    2.  
    3. Remove the clip securing the gear shift cable end to the gear selector adapter.
    4.  
    5. Pull the cable end from the gear selector.
    6.  
    7. Disconnect the clip for the indicator cable and guide tube from the shift cable bracket and move out of the way.
    8.  

  6.  
  7. Remove the nut securing the gear shift cable bracket to the instrument panel frame.
  8.  
  9. Remove the bracket from the instrument panel.
  10.  
  11. Remove the screw and bolt holding the hood release handle to the instrument panel, then set the handle out of the way.
  12.  
  13. Using a very flat pry tool wrapped in a towel to prevent scuffing or damaging the instrument panel pad, disengage the clips holding the rear edge of the instrument panel top cover. Pull up on the cover enough to unplug the wiring harness connector from the message center.
  14.  
  15. Pull the top cover rearward to disengage the hooks that secure the front of the cover to the instrument panel. Remove the instrument panel top cover from the vehicle.
  16.  
  17. Unplug the wire connector from the HVAC wiring harness connector behind the glove box area.
  18.  
  19. Remove the bolts securing the instrument panel frame to the brackets on the cowl side panels.
  20.  
  21. Loosen, but do not remove, the pivot bolts holding the instrument panel to the cowl panels.
  22.  
  23. Remove the bolts securing the instrument panel frame to the dash panel below the windshield opening.
  24.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the instrument panel assembly from the vehicle

  1. With the help of an assistant, remove the instrument panel assembly from the vehicle.
  2.  

To install:
  1. With the help of an assistant, correctly position the instrument panel assembly into the vehicle.
  2.  
  3. Install and tighten the bolts securing the instrument panel frame to the dash panel below the windshield opening.
  4.  
  5. Tighten the pivot bolts holding the instrument panel to the cowl panels.
  6.  
  7. Install and tighten the bolts securing the instrument panel frame to the brackets on the cowl side panels.
  8.  
  9. Plug the wire connector into the HVAC wiring harness connector behind the glove box area.
  10.  
  11. Place the instrument panel top cover onto the instrument panel and plug in the wiring harness connector to the message center. Install the top cover being certain to engage all of the hooks and retaining clips.
  12.  
  13. Place the hood release handle in position on the instrument panel. Install and tighten the mounting screw and bolt.
  14.  
  15. Install the gear shift bracket to the instrument panel.
  16.  
  17. If equipped with a mechanical transmission range indicator, install the indicator cable and guide tube. Install the cable retaining clips.
  18.  
  19. Install and tighten the nuts securing the instrument panel frame to the metal brake pedal support on each side of the steering column.
  20.  
  21. Join the upper steering column shaft to the lower steering column shaft and secure with the clinch bolt.
  22.  
  23. Plug in the two, 40-pin wiring harness connectors to the right of the steering column.
  24.  
  25. Plug in the instrument panel wiring harness connector to body control module.
  26.  
  27. Plug in the lower two, 40-pin wiring harness connectors to the main junction block.
  28.  
  29. Install the knee blocker reinforcement panel.
  30.  
  31. Plug in the antenna lead connector.
  32.  
  33. Install the glove box.
  34.  
  35. Install the A-pillar trim covers.
  36.  
  37. Install the cowl trim covers door sill plates
  38.  
  39. Plug in the wiring harness connector to the passenger air bag module.
  40.  
  41. Install the left and right instrument panel end covers.
  42.  
  43. Install the lower steering column cover. Be sure to install the parking brake release handle.
  44.  
  45. Install the lower supports to the instrument panel frame and floor. Install and tighten the mounting fasteners.
  46.  
  47. Install the lower heat duct into the vehicle.
  48.  
  49. Install the lower instrument panel console assembly.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Test all the instrument on the instrument panel assembly to verify that they operate properly.
  54.  

 
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