TownAndCountry 2008

Instrument Panel

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Removal & Installation




CAUTION
To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait 2 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.


CAUTION
To avoid personal injury or death on vehicles equipped with the Occupant Classification System (OCS), only the Occupant Classification Module (OCM) and the seat cushion trim may be serviced separately. All other components of the passenger side front seat cushion assembly must be serviced only as a complete factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the frame, springs, pad, bladder, sensor, foam, wiring, and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Failure to take the proper precautions could result in failure of the passenger airbag to deploy when required, or in passenger airbag deployment when not required.


WARNING
On vehicles equipped with OCS, never replace both the Occupant Restraint Controller (ORC) and the OCM at the same time. If both require replacement, replace one. Then, perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules.

Removal of the instrument panel involves many screws of different sizes. As you work on each individual trim module, tag and bag the screws to ease installation. Refer to the illustrations to aid in identifying the locations of the securing screws and clips. To avoid damaging the panels, use care when prying the panels to detach their securing clips.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the lower console:
    1. Remove the 5 retaining screws.
    2.  
    3. Pull rearward and disconnect the auxiliary power outlet.
    4.  
    5. Remove the lower console from the vehicle.
    6.  

  6.  
  7. Remove the bolts attaching the lower supports to the instrument panel frame.

    Click image to see an enlarged view

    Fig. Remove the bolts attaching the lower supports to the instrument panel frame

  8.  
  9. Remove the bolts attaching the lower supports to the floor pan.
  10.  
  11. Remove both left and right side A-pillar trim covers using a trim stick Special Tool No. C-4755, or equivalent, to gently pry out on the trim covers and remove.
  12.  
  13. Remove the instrument cluster assembly.

    Click image to see an enlarged view

    Fig. Remove the instrument cluster assembly

  14.  
  15. Remove the message center assembly.
  16.  
  17. Remove the radio assembly.
  18.  
  19. Remove the headlamp switch.
  20.  
  21. Remove the lower console.

    Click image to see an enlarged view

    Fig. Remove the lower console

  22.  
  23. Remove the lower panel.
    1. Remove the right end cover.
    2.  
    3. Remove the lower steering column cover.

      Click image to see an enlarged view

      Fig. Remove the lower steering column cover

    4.  
    5. Remove the center bezel.
    6.  
    7. Remove the lower console.
    8.  
    9. Remove the cup holder and track.
    10.  
    11. Remove the glove box.
    12.  
    13. Remove the glove box latch striker.
    14.  
    15. Remove the glove box lamp.
    16.  
    17. Remove the screws holding the lower instrument panel to the reinforcement frame.
    18.  
    19. Remove the lower instrument panel from the vehicle.

      Click image to see an enlarged view

      Fig. Remove the lower instrument panel from the vehicle

    20.  

  24.  
  25. Remove the instrument panel speakers.
  26.  
  27. Remove the passenger airbag mounting bolts.
  28.  
  29. Loosen the 3 passenger airbag support bracket bolts from the hydro-form rail.

    Click image to see an enlarged view

    Fig. Location of airbag mounting hardware

  30.  
  31. Remove the 16 screws along the upper edge of the pad and panel assembly.
  32.  
  33. Remove the 19 screws along the lower edge of the pad and panel assembly.
  34.  
  35. Remove the pad and panel assembly.
  36.  
  37. Disconnect the wire connectors from the passenger airbag.
  38.  
  39. Remove the screws from the right and left cowl trim covers.
  40.  
  41. Remove the screws attaching the instrument panel frame to the dash panel below the windshield opening.

    Click image to see an enlarged view

    Fig. Remove the screws attaching the instrument panel frame to the dash panel below the windshield opening

  42.  
  43. Disconnect the antenna lead connector from behind the glove box.
  44.  
  45. Disconnect the right side wire connectors from the HVAC behind the glove box area and the antenna connectors behind the glove box hinge.
  46.  
  47. Remove the right end cover by pulling outboard.
  48.  
  49. Remove the right side A-pillar retaining bolts. There are two 13mm bolts and one 10mm bolt.

    Click image to see an enlarged view

    Fig. Remove the right side A-pillar retaining bolts

  50.  
  51. Loosen the right side cowl side roll down bolt.
  52.  
  53. Remove the over steering column cover.

    Click image to see an enlarged view

    Fig. Remove the over steering column cover

  54.  
  55. Remove the cluster bezel.
    1. Remove Over Steering Column Bezel by lifting it straight up with a firm pull.
    2.  
    3. Remove the 4 bezel attaching screws.
    4.  
    5. Tilt the steering column in the full down position.
    6.  
    7. Pull rearward on the cluster bezel and remove.

      Click image to see an enlarged view

      Fig. Remove the cluster bezel

    8.  

  56.  
  57. Remove the lower steering column cover and end cap.
  58.  
  59. Remove the inflatable knee blocker.
  60.  
  61. Remove the 2 screws to the hood release handle.
  62.  
  63. Remove the 2 steering column fixed shroud retaining screws.
  64.  
  65. Remove the 4 steering column shroud retaining screws. Separate the steering column bearing shroud and steering column shroud and remove them from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the steering column shrouds

  66.  
  67. Disconnect the left side wiring:

    Brake switch
     
    Main bulkhead connector
     
    5 harness connectors
     
    Driver airbag connector
     

  68.  
  69. Disconnect the steering column wiring.
  70.  
  71. Disconnect the Occupant Restraint Controller (ORC) harness connector.
  72.  
  73. Remove the 3 nuts retaining the steering column to the dash panel steering column mounting bracket and lower the column to the floor.

    Click image to see an enlarged view

    Fig. Remove the 3 nuts retaining the steering column to the dash panel steering column mounting bracket and lower the column to the floor

  74.  
  75. Remove the 3 nuts attaching the instrument panel to the brake pedal support bracket.
  76.  
  77. Remove the 6 instrument panel steering column cover plate attaching screws and remove the cover plate.
  78.  
  79. Remove the screws attaching the instrument panel reinforcement and remove the panel reinforcement.

    Click image to see an enlarged view

    Fig. Remove the instrument panel column cover plate

  80.  
  81. Remove the left and right power mirrors:
    1. Using a trim stick, or equivalent, gently pry out on the mirror trim cover.
    2.  
    3. Open the door and remove the 3 TORX retaining screws.
    4.  
    5. Disconnect the wire connector and remove the mirror(s) from the vehicle.
    6.  

  82.  
  83. Feed the power mirror wire harness inboard through the A-pillar.
  84.  
  85. Loosen the left side roll down bolt.
  86.  
  87. Remove the left side A-pillar retaining bolts. (There are two 13mm bolts and one 10mm bolt).
  88.  
  89. With the help of an assistant, remove the instrument panel from the vehicle.
    NOTE
    Lift the instrument panel up off the HVAC so you won't damage the sealing surface of the distribution duct.

  90.  
  91. If the instrument panel is being replaced, transfer all parts to the new instrument panel assembly.
  92.  

To install:

  1. With the help of an assistant, place the instrument panel into the vehicle on the roll down bolts.
    NOTE
    As you roll the instrument panel up, lift the instrument panel up so the duct work does not bind or bend and you can set it down on the HVAC housing to get the proper seal at the distribution duct. Get one bolt started in the dash panel.

  2.  
  3. Start the locator screw and install the right side A-pillar retaining bolts. (There are two 13mm bolts and one 10mm bolt).
  4.  
  5. Install the left side A-pillar retaining bolts. (There are two 13mm bolts and one 10mm bolt).
  6.  
  7. Tighten the right and left side cowl side roll down bolts.
  8.  
  9. Feed the power mirror wire harness outboard through the A-pillar.
  10.  
  11. Install the left and right power mirrors:
    1. Connect the wire connector and install the mirror onto the vehicle.
    2.  
    3. Install the 3 TORX retaining screws.
    4.  
    5. Using a firm push, snap the mirror trim cover into place.
    6.  

  12.  
  13. Place the steering column cover plate into position.
  14.  
  15. Install the instrument panel steering column cover plate attaching screws.
  16.  
  17. Install the screws attaching the instrument panel reinforcement.
  18.  
  19. Place the brake pedal support bracket into position and install the 3 nuts attaching it to the instrument panel.
  20.  
  21. Place the steering column into position and install the 4 nuts retaining the steering column to the dash panel steering column mounting bracket.
  22.  
  23. Connect the Occupant Restraint Controller (ORC) harness connector.
  24.  
  25. Connect the steering column wiring.
  26.  
  27. Connect the left side wiring:

    Brake switch
     
    Main bulkhead connector
     
    Five harness connectors
     
    Driver airbag connector
     

  28.  
  29. Place the steering column bearing shroud and steering column shroud into position and install the 4 steering column shroud retaining screws.
  30.  
  31. Place the fixed shroud into position and install the 2 steering column fixed shroud retaining screws.
  32.  
  33. Install the 2 screws to the hood release handle.
  34.  
  35. Install the inflatable knee blocker.
  36.  
  37. Install the lower steering column cover and end cap.
  38.  
  39. Install the cluster bezel.
    1. Maneuver cluster bezel over the steering column and into position.
    2.  
    3. Install the 4 bezel attaching screws.
    4.  
    5. Install the Over Steering Column Bezel by positioning it over the retaining slots and firmly snapping it into place.
    6.  

  40.  
  41. Install the over steering column cover.
  42.  
  43. Install the right end cover. Position it over retaining slots and firmly snap into place.
  44.  
  45. Connect the right side wire connectors to the HVAC behind the glove box area and the antenna connectors behind the glove box hinge.
  46.  
  47. Install the glove box:
    1. Line up the hinges and firmly snap them together.
    2.  
    3. Push in on the sides of the glove box bin and raise the door.
    4.  

  48.  
  49. Install the screws to the right and left cowl trim covers.
  50.  
  51. Connect the wire connectors to the passenger airbag.
  52.  
  53. Install the screws attaching the instrument panel frame to the dash panel below the windshield opening.
  54.  
  55. Install the screws attaching the instrument panel frame to the dash panel below the windshield opening.
  56.  
  57. Position the pan and panel assembly onto the instrument panel support structure.
  58.  
  59. Install the 19 screws along the lower edge of the pad and panel assembly.
  60.  
  61. Install the 16 screws along the upper edge of the pad and panel assembly.
  62.  
  63. Install and tighten the 2 passenger airbag mounting screws.
  64.  
  65. Tighten the 3 passenger airbag support bracket bolts to the hydro-form tube.
  66.  
  67. Install the glove box light.
  68.  
  69. Install the instrument panel speakers.
  70.  
  71. Install the lower panel.
  72.  
  73. Install the lower console.
  74.  
  75. Install the headlamp switch.
  76.  
  77. Install the radio.
  78.  
  79. Install the message center.
  80.  
  81. Install the instrument cluster.
  82.  
  83. Install the left and right side A-pillar trim covers.
  84.  
  85. Install the bolts attaching the lower supports to the floor pan.
  86.  
  87. Install the bolts attaching the lower supports to the instrument panel frame.
  88.  
  89. Install the lower console.
  90.  
  91. Connect the battery negative cable.
  92.  
  93. Check for proper operation of related components.
  94.  

 
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