HOW TO: Replace dead instrument cluster lights

Discussion in 'How To' started by BluPhant, Mar 17, 2005.

  1. BluPhant

    BluPhant Full Access Member

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    As with any electric/electronic project involving ANY car, please remember to disconnect your negative battery terminal prior to starting.

    A quick look in the service manual gives us instructions about how to replace lights in your dash. They are incandescnet lights and should be available at your Jeep dealer.

    The p/n for the lights:04839738AA Cluster has 9 of these bulbs in total.

    CLUSTER BEZEL REMOVAL
    (1) Remove the drives side trim bezels.

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    (1A) Remove the A pillar cover

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    (2) Remove the instrument panel top cover.(lift the left side only to acces cluster screw)

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    (3) Remove the seven screws and remove the cluster bezel.

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    There is a piece of plastic covering this hole for some reason, take of fusebox lid and door seal to take it out / fit it back the right way.

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    CLUSTER REMOVAL
    (1) Disconnect and isolate the battery negative cable.
    (2) Remove the cluster bezel from the instrument panel.
    (BP: See above)

    (3) Remove the four screws that secure the instrument cluster to the instrument panel (Fig. 3).
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    (4) Pull the instrument cluster rearward far enough to access and disconnect the instrument panel wire harness connector for the cluster from the cluster connector receptacle.

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    (5) Remove the instrument cluster from the instrument panel.

    CLUSTER BULB
    This procedure applies to each of the incandescent cluster illumination lamp and bulb holder units.
    (1) Disconnect and isolate the battery negative cable.
    (2) Remove the instrument cluster from the instrument panel.
    (BP: See above)
    (3) Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board (Fig. 4).
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    To reassemble, follow directions in reverse!

    -Blu

    Pics and some extra info added - Tonycrd
     
    Last edited by a moderator: Jan 22, 2009
  2. wildhighlander

    wildhighlander New Member

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    connecting the cluster after change out

    I followed all of the steps (including disconnecting battery.) All of the little idiot lights are still working fine- the gauges all flat-lined. What is the secret to plugging this thing back into the harness? Do I need to get a shop to reset the computer? My odometer is still working, so I'm guessing no information got wiped out. What did I miss? Feel free to point out any stupid detail I overlooked- would like to fix it myself, but if I have to take it to a shop I will take my lumps. Any assistance would be appreciated ](*,)

    (it's great to see the dashboard lit up again, but I would rather have functioning gauges- at least the gps shows my approx speed)
     
  3. BluPhant

    BluPhant Full Access Member

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    Hey-

    You should be able to just reconnect and be fine. Here's instructions on how to test the instrument cluster... let us know how it goes, I'll see if I can dig up anything else. I assume you checked the connection on the back of the bezel, that would be my first guess. If this test passes, you may have a lil project on your hands. It could be as simple as a fuse somewheres tho.........

    -Blu

    The instrument cluster actuator test will put the
    instrument cluster into its self-diagnostic mode. In
    this mode the instrument cluster can perform a selfdiagnostic
    test that will confirm that the instrument
    cluster circuitry, the gauges, the PCI data bus message
    controlled indicator lamps, and the chime tone
    generator are capable of operating as designed. During
    the actuator test the instrument cluster circuitry
    will sound the chime tone generator, position each of
    the gauge needles at various specified calibration
    points, illuminate each of the segments in the Vacuum-
    Fluorescent Display (VFD), and turn all of the
    PCI data bus message-controlled indicators on and
    off again.
    Successful completion of the actuator test will confirm
    that the instrument cluster is operational. However,
    there may still be a problem with the PCI data
    bus, the Powertrain Control Module (PCM), the Airbag
    Control Module (ACM), the Sentry Key Immobilizer
    Module (SKIM), or the inputs to one of these
    electronic control modules. Use a DRBIIIt scan tool
    to diagnose these components. Refer to the appropriate
    diagnostic information.
    (1) Begin the test with the ignition switch in the
    Off position.
    (2) Depress the odometer/trip odometer switch button.
    (3) While still holding the odometer/trip odometer
    switch button depressed, turn the ignition switch to
    the On position, but do not start the engine.
    (4) Release the odometer/trip odometer switch button.
    (5) The instrument cluster will automatically
    begin the actuator test sequence, as follows:
    (a) The cluster will turn on, then off again each
    of the PCI data bus message controlled indicators
    to confirm the functionality of the indicator and
    the cluster control circuitry:
    (b) The cluster will sweep the needles for each of
    the gauges to several calibration points in sequence
    to confirm the functionality of the gauge and the
    cluster control circuitry:
    (c) The cluster will sequentially step the odometer/
    trip odometer VFD display from all ones
    (111111) through all nines (999999) to confirm the
    functionality of all VFD segments and their control
    circuitry, then display the software version number.
    (d) The cluster will generate five (5) chime tones
    to confirm the functionality of the chime tone generator
    and the chime control circuitry.
    (6) The actuator test is now completed. The instrument
    cluster will automatically exit the self-diagnostic
    mode and return to normal operation at the
    completion of the test, if the ignition switch is turned
    to the Off position during the test, or if an engine
    rpm message indicating that the engine is running is
    received from the PCM over the PCI data bus during
    the test.
    (7) Go back to Step 1 to repeat the test, if
    required.
     
  4. wildhighlander

    wildhighlander New Member

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    self diagnostic

    Ran the test twice. Everything checked out. Got the tones at the conclusion- but the needles never moved. Looks like I have a project on my hands. Already did some checking and I can pick up an '02 cluster for under 20 bucks.

    Thanks for responding with the test info.
     
  5. BluPhant

    BluPhant Full Access Member

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    Good luck with it, let us know how it goes. Hopefully the new cluster will help out. I don't even know if this would help, but I can't see it hurting-- you might want to go through and check your fuses, make sure nothings blown. If you want I could go thru the schematics and see which would be affected, if any.... I just cant reconcile how both of your needles could be dysfunctional given what you did, and I'm wondering if the problem might be upstream from the gages.

    In any case, let us know what you're doing and how it works out.

    -=\Blu/=-
     
  6. wildhighlander

    wildhighlander New Member

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    gauges working again !

    I got the problem fixed- FINALLY. At the risk of sounding like a [email protected]$$, it was entirely my fault. No, I didn't blow any fuses. Worse, when I replaced the needles, apparently I pressed them on a bit too firmly. I shouldn't use the word "apparently"... change that to obviously. There wasn't anything mechanically or electronically wrong with the gauges. I have to chalk this one up to a brainfart on the part of the "mechanic." #-o

    THANKS again for all of your help.
     
  7. myakubis

    myakubis New Member

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    Thanks for the forum, hope it isn't too inactive. BTW I recomend the Haynes manual for everyone. Anyways, I have had no help with forums about installing EL glow gauges, so I am going to do an install hopefully this week on my Liberty and I was wondering if anyone knew how to access the headlight wiring (from the fusebox or switch) to either solder or splice the wires to. Wish me luck and I plan on posting my own forum to help anybody else planning a DIY gauge job. Thanks for all the help!

    -YAK
     
  8. BluPhant

    BluPhant Full Access Member

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    heres a snippit from the wiring diagrams in the service manual. Not sure exactly what wire you're looking for (parking light switched or the one controlled by the dimmer?)

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  9. myakubis

    myakubis New Member

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    Thanks. I decided that since the on/off switch for the gauge face would react with the multi-function switch, I would just pull off the radio/AC bezel and tap into the 12v outlet. Installation was quick and relatively simple. Thanks for all the help!!!
     
  10. BluPhant

    BluPhant Full Access Member

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    pics2.gif
     
  11. KevinCRD

    KevinCRD New Member

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    Hello everyone
    I have a doubt about the reference of the bulbs.
    As they appear in the answer # 1 the reference of the bulbs is 04839738AA but according to the attached document on the KJ '04, the reference is 04827989AA
    can anyone confirm whether the two references are correct?

    Greetings. KevinCRD
     

    Attached Files:

  12. desertkj

    desertkj Full Access Member

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    Just had to say thanks for posting this write-up. Just came in from the garage and it was very easy other than getting the wrong light bulbs (double check the part #'s!). Saved at least $200 from having the dealer do it.
     
  13. desertkj

    desertkj Full Access Member

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    Mine shows the 10-04839738AA that was posted before. However, when the computer ran the part number, it mentioned that I needed PC74 bulbs. Then, in the owner's manual, it shows bulb "103" for "instrument cluster replacement." So, it is indeed the 04839738AA that is listed previously, despite what the computer or manual may say.
     
  14. Stream

    Stream New Member

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    Awesome write up, once the instrument cluster is out, would it be easy enough to remove the perspex cover, mine is cracked and needs replacing.

    Thanks
     
  15. BlackDiamond

    BlackDiamond New Member

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    I want to say thank you for this great HowTo =D>

    It took me about half an hour to replace the bulbs and reassemble everything. Now the instrument panel of my 2002 KJ has even illumination again (biggthumpup)

    I ordered the bulbs from the Mopar e-store but I could only find part code 04827989AA available for ordering (anyway 04827989AA is the code that I have on the KJ 2002 parts list)

    Lights 04827989AA are identical to the ones that I had on my instrument panel except for the color of the socket which is black instead than red. They come in 10pcs packages.

    Part code 04839738AA actually exists but it's not available for ordering.
     
  16. hyde

    hyde Moderator KJ Supporting Member

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    Does anyone know if all KJ instrument panels are interchangeable? Can we get 01 in 06, etc? They are swapped in some models, so I wouldn't want the rmp to show speed and vice versa. :) This is just a general question if someone was interested in getting our Limited white background gauges.
     
  17. Uncle Krusty

    Uncle Krusty Full Access Member

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    My '06 has the Speedo on the left (looking at the dash) and the Tach on the right. If I remember correctly, this was just opposite an '04 I looked at once.

    BTW, My Limited has dark backgroung guages...
     
  18. Quiksilver21

    Quiksilver21 New Member

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    are the bulbs in clusters?

    I want to take the CEL light out - i'm running the ORM which sets it off. So want to disable it.

    I have a scan tool so can check for errors through that periodically - just want to get rid of the light.

    But obviously not turn a whole corner of the dash off
     
  19. UC3Caveman

    UC3Caveman New Member

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    A little off topic, but what is that roller switch to the right side of the steering wheel for?
     
  20. hmmrdwn

    hmmrdwn Full Access Member

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    Thanks. This is why I love the internet. There were 9 bulbs. Replaced all and kept ones that work. Really helps an old gauge cluster.