Content .. 300 301 302 303 ..

Jeep Wrangler TJ. Manual - part 302

DISASSEMBLY

Some of the components for the instrument cluster

used in this vehicle are serviced individually. The
serviced

components

include:

the

incandescent

instrument cluster indicator and illumination lamp
bulbs (including the integral bulb holders), the clus-
ter lens, the trip odometer reset button boot, the
cluster hood and mask unit, and the cluster housing
rear cover. Following are the procedures for disas-
sembling these components from the instrument clus-
ter unit.

WARNING:

AVOID

PERSONAL

INJURY

DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM

BEFORE

ATTEMPTING

ANY

STEERING

WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.

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 instru-

ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).

(3) Turn the bulb holder counterclockwise about

sixty degrees on the cluster electronic circuit board
(Fig. 5).

(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

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument cluster from the instru-

ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).

(3) Work around the perimeter of the cluster lens

and disengage each of the eight latches that secure
the lens to the cluster mask and the cluster housing
(Fig. 6).

(4) Gently pull the cluster lens away from the face

of the instrument cluster.

TRIP ODOMETER RESET BUTTON BOOT

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument cluster from the instru-

ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).

(3) Remove the cluster lens from the cluster hous-

ing. Refer to CLUSTER LENS.

(4) Remove the odometer reset button boot by pull-

ing it straight out of the pocketed hole from the face
of the cluster lens (Fig. 6).

Fig. 4 Instrument Cluster Remove/Install

1 - WIRE HARNESS CONNECTORS
2 - INSTRUMENT CLUSTER
3 - SCREW (4)
4 - INSTRUMENT PANEL

Fig. 5 Cluster Bulb Locations

1 - CLUSTER INCANDESCENT BULBS

INSTRUMENT CLUSTER

8J - 17

INSTRUMENT CLUSTER (Continued)

CLUSTER HOOD AND MASK

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument cluster from the instru-

ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).

(3) Remove the cluster lens from the cluster hous-

ing. Refer to CLUSTER LENS.

(4) Work around the perimeter of the cluster hood

and mask unit and disengage each of the five latches
that secure the cluster hood and mask unit to the
cluster housing (Fig. 6).

(5) Gently pull the cluster hood and mask unit

away from the face of the instrument cluster hous-
ing.

CLUSTER HOUSING REAR COVER

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument cluster from the instru-

ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).

(3) Remove the screw adjacent to each of the two

cluster connector receptacles that secure the rear
cover to the cluster housing.

(4) Work around the perimeter of the cluster hous-

ing rear cover and disengage each of the eight
latches that secure the cover to the outside of the
cluster housing (Fig. 6).

(5) Disengage the one inboard latch located in a

receptacle near the lower edge of the rear cover just
to the right of center that secures the rear cover to
the cluster housing.

(6) Gently pull the cluster housing rear cover away

from the back of the cluster housing.

ASSEMBLY

Some of the components for the instrument cluster

used in this vehicle are serviced individually. The
serviced

components

include:

the

incandescent

WARNING:

AVOID

PERSONAL

INJURY

DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM

BEFORE

ATTEMPTING

ANY

STEERING

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 elec-
tronic 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. 5).

(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 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).

(4) Reconnect the battery negative cable.

Fig. 6 Instrument Cluster Components

1 - REAR COVER
2 - CLUSTER HOUSING
3 - CLUSTER HOOD & MASK
4 - CLUSTER LENS
5 - SWITCH BUTTON BOOT

8J - 18

INSTRUMENT CLUSTER

INSTRUMENT CLUSTER (Continued)

CLUSTER LENS

(1) Position the cluster lens over the cluster hood

and mask unit on the face of the instrument cluster
(Fig. 6). Be certain that the trip odometer reset
switch button is aligned with and inserted into the
reset button boot in the lens.

(2) Press firmly and evenly on the cluster lens to

install it onto the instrument cluster housing.

(3) Work around the perimeter of the cluster lens

making certain that each of the eight latches that
secure the lens to the cluster mask and the cluster
housing is fully engaged.

(4) Reinstall

the

instrument

cluster

onto

the

instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).

(5) Reconnect the battery negative cable.

TRIP ODOMETER RESET BUTTON BOOT

(1) Position the trip odometer reset button boot

into the pocketed mounting hole from the back of the
cluster lens (Fig. 6).

(2) Gently pull the tip of the trip odometer reset

button boot from the face of the cluster lens until it
is fully seated in the pocketed mounting hole.

(3) Reinstall the cluster lens onto the cluster hous-

ing. Refer to CLUSTER LENS.

(4) Reinstall

the

instrument

cluster

onto

the

instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).

(5) Reconnect the battery negative cable.

CLUSTER HOOD AND MASK

(1) Align the cluster hood and mask unit with the

face of the instrument cluster housing (Fig. 6).

(2) Press firmly and evenly on the cluster hood

and mask unit to install it onto the cluster housing.

(3) Work around the perimeter of the cluster hood

and mask unit making certain that each of the five
latches that secure the hood and mask unit to the
instrument cluster housing is fully engaged.

(4) Reinstall the cluster lens onto the cluster hous-

ing. Refer to CLUSTER LENS.

(5) Reinstall

the

instrument

cluster

onto

the

instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).

(6) Reconnect the battery negative cable.

CLUSTER HOUSING REAR COVER

(1) Position the cluster housing rear cover to the

back of the instrument cluster housing.

(2) Press firmly and evenly on the cluster housing

rear cover to install it onto the back of the instru-
ment cluster housing.

(3) Work around the perimeter of the cluster hous-

ing rear cover making certain that each of the eight

latches that secure the rear cover to the instrument
cluster housing is fully engaged.

(4) Install and tighten the two screws that secures

the rear cover to the instrument cluster housing
adjacent to each cluster connector receptacle. Tighten
the screws to 2 N·m (20 in. lbs.).

(5) Reinstall

the

instrument

cluster

onto

the

instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).

(6) Reconnect the battery negative cable.

INSTALLATION

WARNING:

AVOID

PERSONAL

INJURY

DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM

BEFORE

ATTEMPTING

ANY

STEERING

(1) Position the instrument cluster to the instru-

ment panel.

(2) Reconnect the two instrument panel wire har-

ness connectors for the cluster to the connector recep-
tacles on the back of the cluster housing (Fig. 4).

(3) Position the instrument cluster into the instru-

ment panel structural support.

(4) Install and tighten the four screws that secure

the instrument cluster to the instrument panel struc-
tural support. Tighten the screws to 2.2 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.

NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated for deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the airbag indicator, the cruise indicator,
or the SKIM indicator when the vehicle does not
have this equipment, the instrument cluster must
be replaced with a new unit.

INSTRUMENT CLUSTER

8J - 19

INSTRUMENT CLUSTER (Continued)

ABS INDICATOR

DESCRIPTION

An Antilock Brake System (ABS) indicator is stan-

dard equipment on all instrument clusters (Fig. 7).
However, this indicator is only functional on vehicles
equipped with the ABS option. The ABS indicator is
located near the lower edge of the instrument cluster,
to the left of center. The ABS indicator consists of a
stencil-like cutout of the International Control and
Display Symbol icon for “Failure of Anti-lock Braking
System” in the opaque layer of the instrument clus-
ter overlay. The dark outer layer of the overlay pre-
vents the indicator from being clearly visible when it
is not illuminated. An amber Light Emitting Diode
(LED) behind the cutout in the opaque layer of the
overlay causes the icon to appear in amber through
the translucent outer layer of the overlay when the
indicator is illuminated from behind by the LED,
which is soldered onto the instrument cluster elec-
tronic circuit board. The ABS indicator is serviced as
a unit with the instrument cluster.

OPERATION

The ABS indicator gives an indication to the vehi-

cle operator when the ABS system is faulty or inop-
erative.

This

indicator

hard

wired

the

instrument cluster electronic circuit board, and is
completely controlled by the Controller Antilock
Brake (CAB). The ABS indicator Light Emitting
Diode (LED) receives battery current on the instru-
ment cluster electronic circuit board through the
fused ignition switch output (run-start) circuit when-
ever the ignition switch is in the On or Start posi-
tions; therefore, the LED will always be off when the
ignition switch is in any position except On or Start.
The LED only illuminates when it is provided a path
to ground by the CAB through the CAB relay in the
Power Distribution Center (PDC). The CAB will turn
on the ABS indicator for the following reasons:

• Bulb Test - Each time the ignition switch is

turned to the On position the ABS indicator is illu-
minated by the cluster for about two seconds as a
bulb test.

• ABS Self-Test Fault - Each time the CAB

detects a fault in a monitored ABS circuit, the ABS
indicator will be illuminated. The indicator remains
illuminated until the fault condition is corrected, or
until the ignition switch is turned to the Off position,
whichever occurs first.

• ABS Diagnostic Test - The ABS indicator is

blinked on and off by the CAB during the perfor-
mance of the ABS diagnostic tests.

The CAB continually monitors the ABS circuits

and sensors to decide whether the system is in good
operating condition. If the CAB turns the ABS indi-
cator on after the bulb test, it indicates that the CAB
has detected a system malfunction and/or that the
ABS system has become inoperative. The CAB will
store a Diagnostic Trouble Code (DTC) for any mal-
function

detects.

(Refer

BRAKES

DESCRIPTION). The ABS indicator can be diagnosed
using conventional diagnostic tools and methods.

DIAGNOSIS AND TESTING - ABS INDICATOR

The diagnosis found here addresses an inoperative

Antilock Brake System (ABS) indicator condition. If
there are problems with several indicators in the
instrument cluster, (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - DIAGNOSIS AND TEST-
ING). If the ABS indicator stays on with the ignition
switch in the On position or comes on and stays on
while driving, proceed to the diagnosis for the ABS
brake system. (Refer to 5 - BRAKES - DIAGNOSIS
AND TESTING). If no ABS problem is found, the fol-
lowing procedure will help to locate a short or open
in the ABS warning indicator driver circuit. Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.

WARNING:

AVOID

PERSONAL

INJURY

DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM

BEFORE

ATTEMPTING

ANY

STEERING

(1) Disconnect and isolate the battery negative

cable. Remove the instrument cluster from the
instrument panel. Disconnect the instrument panel
wire harness connector (Connector C2) for the instru-
ment cluster from the connector receptacle on the
back of the cluster housing. Reconnect the battery
negative cable. Turn the ignition switch to the On

Fig. 7 ABS Indicator

8J - 20

INSTRUMENT CLUSTER

Content .. 300 301 302 303 ..