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TSB 08-05-00

Intermittent Operation Of The Instrument Cluster

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Date: April 21, 2000

Models:
1999  (AB) Ram Van/Wagon
1999  (AN) Dakota
1999  (BR/BE) Ram Truck
1999  (DN) Durango

Discussion:
This bulletin involves replacing the instrument cluster wire harness connector and associated wire terminals.

Symptoms:

The needle of the instrument cluster gauges may intermittently drop to zero and/or the telltale lamps, such as the AIRBAG warning lamp, may intermittently come on.

Diagnosis:
Connect the DRB lll to the 16-way Data Link Connector (DLC). Read and record all active and stored Airbag Control Module (ACM) Diagnostic Trouble Codes (DTC). If active and/or stored "No Cluster CCD Bus" DTC is present, perform the Repair Procedure.

Parts:
1 05016640AA   Kit, Instrument Cluster Harness Connector Wiring Repair
                            Kit Includes:
                            (1) Cluster Connector With Terminated Wires
                            (1) Pink Wire With Terminal
                            (1) Yellow Wire With Terminal
                            (1) Black Wire With Terminal
                            (1) Black/Orange Wire With Terminal
                           (10) Heat Shrink Tubing
                           (12) Splice Bands

Equipment Required:
Soldering Gun
Rosin Core Solder
Heat Gun

Repair:
1.     Disconnect and isolate the battery negative cable. On vehicles equipped with the 5.9L Cummins diesel engine, disconnect and isolate both battery negative cables.

2.     Remove the instrument cluster bezel. Refer to the appropriate Service Manual, Group SE, for information regarding Instrument Cluster Bezel removal.

3.     Remove the four screws that secure the instrument cluster to the instrument panel (Figure 1).

4.     If the vehicle is equipped with an automatic transmission, place the automatic transmission gear selector into the PARK position and perform Steps 5 and 6. If the vehicle is equipped with a manual transmission, set the parking brake and proceed to Step 7.

5. Remove the steering column opening cover.

a.    On Dakota/Durango/Ram Truck Models, remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 2). Using a trim stick or other suitable wide flat- bladed tool, gently pry the upper edge of the opening cover just below the cluster bezel on each side of the steering column away from the instrument 'panel far enough to disengage the snap clip retainers from the receptacles in the instrument panel. Then, remove the steering column opening cover from the instrument panel.

 

b.     On Ram Van/Wagons, move tilt steering column to the fully raised position, (if equipped). Remove the end cap from the left end of the instrument panel. Remove the three screws that secure the lower edge of the steering column opening cover to the knee blocker. Remove the two screws that secure the outboard end of the steering column opening cover to the left side of the instrument panel end bracket. Using a trim stick or other suitable wide flat- bladed tool, gently pry the upper edge of the opening cover just below the cluster bezel to disengage the four snap clip retainers that secure the cover to the instrument panel. Then, remove the steering column opening cover from the instrument panel.

6.     Disconnect the shift indicator from the steering column (Figure 3).

7.     Pull the instrument cluster rearward far enough to disengage the two self-docking instrument panel wire harness connectors from the connector receptacles on the back of the cluster housing.

8.     Remove the instrument cluster from the instrument panel.

9.     Separate the right side (passenger side) wire harness connector from the self-docking receptacle on the instrument panel.

10.    From the back of the right side instrument cluster wire harness connector, remove approximately three inches of the electrical wire wrapping tape.

11.    Assemble the new instrument panel wire harness connector p/n 05016640AA by inserting the appropriate color-coded terminal/wire into the appropriate wire terminal cavity. The charts on the following page identify proper wire color code connector cavity locations.

  
Instrument Cluster C1 Connector

12.    Push in the wire connector primary lock. The red primary lock in its proper position, when the lock is flush with the back of the housing.

13.    Use one of the two following methods to splice the wires from the new connector t the wires from the original connector. It is recommended to cut and splice one wire at a time to help prevent accidentally splicing the wrong wires together. The previous charts should be used to ensure that the proper wires are spliced together. Splice joints should be staggered about 1/2 in. apart to help limit the size of the wire bundle.

CAUTION:     SOME VEHICLES HAVE MORE THAN ONE WIRE WITH THE SAME COLOR COMBINATION. IT IS NOT ADVISED TO CUT ALL OF THE CONNECTOR WIRES AT ONCE.

WIRE SPLICING METHODS

INSTALLATION

1.     Secure the bundle of wires together using electrical tape.

2.     Install the instrument cluster wire harness connector into the self-docking receptacle.

3.     Position the instrument cluster to the instrument panel.

4.     If the vehicle is equipped with a manual transmission, proceed to Step 6. If the vehicle is equipped with an automatic transmission, install the PRNDL cable onto the steering column PRNDL lever.

5.     Install the steering column opening cover.

a.     On Dakota/Durango/Ram Truck, position the steering column opening cover to the instrument panel. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. Press firmly on the steering column opening cover over the snap clip locations until each snap clip is fully engaged in its receptacle. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 Nom (20 in. lbs.).

b.     On Ram Van/Wagon, position the steering column opening cover to the instrument panel. Align the four snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. Press firmly on the steering column opening cover over the snap clip locations until each snap clip is fully engaged in its receptacle. Install and tighten the two screws that secure the outboard end of the steering column opening cover to the left instrument panel end bracket. Tighten the screws to 2.2 Nm (20 in. lbs.). Install and tighten the three screws that secure the lower edge of the steering column opening cover to the knee blocker. Tighten the screws to 2.2 Nm (20 in. lbs.). Install the end cap onto the left end of the instrument panel.

6.     Align the instrument cluster with the cluster opening in the instrument panel and push the cluster firmly and evenly into place. The instrument panel has two self-docking wire harness connectors that will be automatically aligned with, and connected to the instrument cluster connector receptacles when the cluster is installed in the instrument panel.

7.     Install and tighten the four screws that secure the instrument cluster to the instrument panel. Tighten the screws to 2.2 Nom (20 in. lbs.).

8.     Install the cluster bezel onto the instrument panel. Refer to the appropriate Service Manual, Group 8E, for information regarding Instrument Cluster Bezel installation.

9.     Connect the battery negative cable(s).

10.     Reset the clock in the radio and verify proper operation of the cluster.

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 08-90-90-96 .................................. 1.3 Hrs.

FAILURE CODE. P8 - New Part


Thanks to Bob Bergevin for supplying this TSB information

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This page was edited on: May 3, 2004