2004 CHRYSLER VOYAGER instrument cluster

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. ERRATIC MESSAGE
FROM ANOTHER
MODULE.1.A. CHECK THE BCM USING A DRB IIITSCAN TOOL IF
OK, GO TO STEP 1.B. IF NOT OK, REFER TO THE
PROPER BODY DIAGNOSTIC PROCEDURES MANUAL
TO REPAIR THE BCM.
1.B. CHECK THE PCM USING A DRB IIITSCAN TOOL. IF
OK, GO TO STEP 1.C. IF NOT OK, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC PROCEDURES
MANUAL TO REPAIR THE PCM.
1.C. CHECK THE SPEED SIGNAL INPUT INTO THE PCM.
THE SPEED SIGNAL ORIGINATES FROM THE TCM FOR
VEHICLES WITH THE 4 SPEED ELECTRONIC
TRANSMISSIONS. CHECK CONTINUITY FROM TCM TO
PCM. IF OK, USE A DRB IIITSCAN TOOL TO CHECK
TCM. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE
TCM. IF NOT OK, REPAIR WIRING.
2. INTERNAL CLUSTER
FAILURE.2.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND
CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT STILL
APPEARS ERRATIC, THEN GO TO STEP 2.B.
2.B. REPLACE CLUSTER ASSEMBLY.
SPEEDOMETER
INACCURATE.1. SPEEDOMETER OUT
OF CALIBRATION.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
²IF SPEEDOMETER IS ACCURATE TO THE
CALIBRATION POINTS THEN LOOK FOR ANOTHER
POSSIBLE CAUSE OF INACCURACY.
²IF SPEEDOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY.
2. WRONG
SPEEDOMETER PINION
FOR TIRE SIZE.2.A. IF VEHICLE HAS A 4 SPEED ELECTRONIC
TRANSMISSION GO TO STEP 2.C. OTHERWISE GO TO
STEP 2.B.
2.B. CHECK IF CORRECT SPEEDOMETER PINION IS
BEING USED WITH TIRES ON VEHICLE. REFER TO
TRANSMISSION FOR DIAGNOSIS AND TESTING.
²IF THE INCORRECT PINION IS IN TRANSMISSION
THEN REPLACE WITH CORRECT PINION.
²IF THE CORRECT PINION IS IN THE TRANSMISSION,
CHECK TIRE SIZE.
2.C. USE A DRB IIITSCAN TOOL TO CHECK THE TCM
TO SEE IF THE CORRECT TIRE SIZE HAS BEEN
PROGRAMMED INTO THE TCM.
²IF THE INCORRECT TIRE SIZE WAS SELECTED,
SELECT THE PROPER TIRE SIZE.
²IF THE CORRECT TIRE SIZE WAS SELECTED, CHECK
SPEED SENSOR.
3. BAD SPEED SENSOR. 3. REFER TO TRANSMISSION, SPEED SENSOR,
DIAGNOSIS AND TESTING.
RSINSTRUMENT CLUSTER8J-5
INSTRUMENT CLUSTER (Continued)

TACHOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT.1. INTERNAL
CLUSTER FAILURE.1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND
CHECK FOR FAULT CODES.
²IF TACHOMETER POINTER MOVES TO CALIBRATION
POINTS DURING TEST, LOOK FOR ANOTHER POSSIBLE
CAUSE OF FAILURE.
²IF THE POINTER DOESN'T MOVE DURING TEST,
CHECK FOR POWER AND GROUND TO THE MIC. IF
POWER AND GROUND ARE PRESENT GO TO STEP 1.B.
1.B. REPLACE CLUSTER. GO TO STEP 1.C.
2.9NO RPM9PCI BUS
MESSAGE OR9ZERO
RPM9PCI BUS
MESSAGE FROM
PCM.2. CHECK THE PCM USING A DRB IIITSCAN TOOL.
REFER TO THE PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
REPAIR.
ERRATIC POINTER
MOVEMENT.1. BAD PCI BUS
MESSAGE FROM
PCM.1. CHECK THE PCM USING A DRB IIITSCAN TOOL.
REFER TO THE PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
REPAIR.
2. INTERNAL
CLUSTER FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND
CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT STILL
APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY.
TACHOMETER
INACCURATE.TACHOMETER OUT
OF CALIBRATION.PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
²IF TACHOMETER IS ACCURATE TO THE CALIBRATION
POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF
INACCURACY.
²IF TACHOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY.
8J - 6 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)

FUEL GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT.1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
²IF FUEL GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
²IF THE POINTER DOESN'T MOVE DURING TEST,
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER ASSEMBLY. IF NO, DETERMINE CAUSE
OF NO POWER OR GROUND.
2. NO PCI FUEL
MESSAGE OR EMPTY
PCI BUS MESSAGE
FROM BODY CONTROL
MODULE.2.A. CHECK THE BCM USING A DRB IIITSCAN
TOOL. IF OK, GO TO STEP 2.B. IF NOT OK, REFER
TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2.B. REFER TO THE FUEL SECTION OF THE
SERVICE MANUAL FOR THE FUEL LEVEL SENDING
UNIT TEST PROCEDURE. TEST UNIT AND REPAIR
AS INSTRUCTED.
ERRATIC POINTER
MOVEMENT.1. BAD PCI FUEL
MESSAGE FROM THE
BODY CONTROLLER.1. USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, GO TO STEP 2. IF NOT OK, REFER TO THE
PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL TO PROPERLY DIAGNOSE AND REPAIR.
2. REFER TO THE FUEL SECTION OF THE SERVICE
MANUAL FOR THE FUEL LEVEL SENDING UNIT
TEST PROCEDURE. TEST UNIT. IF OK, LOOK FOR
ANOTHER POSSIBLE CAUSE FOR FUEL GAUGE
FAILURE. IF NOT OK, REPAIR SENDING UNIT.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
FUEL GAUGE
INACCURATE.1. FUEL GAUGE OUT OF
CALIBRATION.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF
POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE. IF POINTER IS INACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. FUEL LEVEL SENDING
UNIT IS OUT OF
CALIBRATION.2. REFER TO THE FUEL SECTION OF THE SERVICE
MANUAL FOR TESTING AND REPAIR PROCEDURE.
RSINSTRUMENT CLUSTER8J-7
INSTRUMENT CLUSTER (Continued)

TEMPERATURE GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT.1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK.
²IF TEMPERATURE GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
²IF THE POINTER DOESN'T MOVE DURING TEST,
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER. IF NO, DETERMINE CAUSE OF NO
POWER OR NO GROUND.
2. NO PCI
TEMPERATURE
MESSAGE OR COLD PCI
BUS MESSAGE FROM
THE POWERTRAIN
CONTROL MODULE.2.A. CHECK PCM FAULT CODES USING A DRB IIIT
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 2.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
ERRATIC POINTER
MOVEMENT.1. BAD PCI BUS
MESSAGE FROM THE
POWERTRAIN CONTROL
MODULE.1.A. CHECK PCM FAULT CODES USING A DRB IIIT
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 1.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
1.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
TEMPERATURE GAUGE
INACCURATE.1. TEMPERATURE
GAUGE OUT OF
CALIBRATION.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
²IF POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE.
²IF POINTER IS INACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. COOLANT SENSOR
OUT OF CALIBRATION.2. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR FOR TEST AND REPAIR PROCEDURE.
8J - 8 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)

ODOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO DISPLAY. 1. NO PCI BUS
ODOMETER MESSAGE
FROM BCM.1. USE A DRB IIITSCAN TOOL TO CHECK THE
BCM. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF ODOMETER PASSES THE SEGMENT CHECK,
LOOK FOR ANOTHER POSSIBLE CAUSE OF
FAILURE. IF IT FAILS VERIFY POWER AND
GROUND ARE BEING PROVIDED TO THE
CLUSTER. IF YES, REPLACE CLUSTER. IF NO,
DETERMINE CAUSE OF NO POWER OR GROUND.
ERRATIC DISPLAY 1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF ODOMETER PASSES THE SEGMENT TEST,
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. VERIFY GOOD POWER AND GROUND
CONNECTIONS. IF CONNECTIONS ARE GOOD AND
NO OTHER PROBLEMS ARE FOUND, REPLACE
CLUSTER ASSEMBLY.
2. BAD PCI BUS
MESSAGE FROM THE
BCM.2. USE A DRB IIITSCAN TOOL TO CHECK THE
BCM. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
ODOMETER WON'T GO
INTO TRIP MODE.TRIP SWITCH DOESN'T
WORK.IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
MODE AND CANNOT TOGGLE BETWEEN
ODOMETER AND TRIP ODOMETER, REPLACE
CLUSTER.
TRIP ODOMETER WON'T
RESET.RESET SWITCH
DOESN'T WORK.IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
MODE AND TRIP ODOMETER WILL NOT RESET,
REPLACE CLUSTER.
RSINSTRUMENT CLUSTER8J-9
INSTRUMENT CLUSTER (Continued)

ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO DISPLAY. 1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF
IT FAILS, REPLACE CLUSTER ASSEMBLY.
ERRATIC DISPLAY. 1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. BAD PCI BUS
MESSAGE FROM THE
TCM.2. USE A DRB IIITSCAN TOOL TO CHECK THE
TCM. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
ALL SEGMENTS ARE ON. 1. NO PCI BUS
MESSAGE FROM THE
TCM.1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REPLACE CLUSTER ASSEMBLY.
1.B. CHECK THE TCM USING A DRB IIITSCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(3) Remove the four cluster bezel attaching screws.
(4) Tilt the steering column in the full down posi-
tion.
(5) Pull rearward on the cluster bezel and remove.
(6) Remove the four screws holding instrument
cluster to instrument panel.
(7) Rotate top of cluster outward.
(8) Disconnect the cluster harness connector.
(9) Remove instrument cluster from instrument
panel.
INSTALLATION
(1) Connect the instrument cluster wire connector.
(2) Rotate top of cluster inward as placing into
instrument panel opening.
(3) Install the four screws holding instrument clus-
ter to instrument panel.
(4) Position cluster bezel into place.(5) Install the four bezel attaching screws.
(6) Install the Over Steering Column Bezel by
firmly snapping into place.
(7) Connect the battery negative cable.
CLUSTER LENS
REMOVAL
(1) Remove the instrument cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Remove the screws holding the lens to the
instrument cluster.
(3) Press down on the snap features of the lens
and remove the lens from the cluster.
INSTALLATION
(1) Insert the lens snap features into the cluster.
(2) Install the screws holding the lens to the
instrument cluster.
(3) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
8J - 10 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)

OPERATION - TURN SIGNAL SYSTEM
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Multi-function switch
²Body Control Module
²Integrated Power Module (IPM)
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 1.0 mile and a speed of 15
mph, with the turn signal ON.
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the resistance read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
MULTI-FUNCTION SWITCH RESISTANCE table.
MULTI-FUNCTION SWITCH RESISTANCE
SWITCH
POSITIONPIN NUMBER RESISTANCE
LEFT 2 AND 3 2.7V 5%
RIGHT 2 AND 3 1KV 5%
OPTICAL
HORN2 AND 4 1.7KV 5%
HI BEAM 2 AND 4 2.32KV 5%
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove upper and lower steering column
shrouds. Refer to Steering, Column, Shroud,
Removal.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
INSTALLATION
(1) Position the switch on to the steering column.
(2) Install the two retaining screws.(3) Connect the wire harness connector.
(4) Install the upper and lower steering column
shrouds. Refer to Steering, Column, Shroud, Installa-
tion.
(5) Connect the battery negative cable.
PARK/TURN SIGNAL LAMP
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
(3) Twist socket counter - clockwise and remove
(Fig. 21).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Twist socket into headlamp.
(3) Install headlamp retaining screws.
(4) Reconnect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 22).
(4) Pull bulb from lamp socket.
Fig. 21 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
8L - 18 LAMPS/LIGHTING - EXTERIORRS
MULTI-FUNCTION SWITCH (Continued)

LAMP BULB
VISOR VANITY 6501966
VOLTAGE INDICATOR LED
* VFD = VACUUM FLUORESCENT DISPLAY
CENTER CONSOLE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open up console lid.
(3) Remove console tray.
(4) Using a trim stick (special tool #C-4755) or
equivalent, gently pry down on lamp. Make sure not
to let lamp fall into console base.
NOTE: If preferred, a 5/16 piece of hose approxi-
mately 4±6 inches long may be used to pull lamp
from socket. Push hose over end of lamp and pull
down.
INSTALLATION
NOTE: If preferred, a 5/16 piece of hose approxi-
mately 4±6 inches long may be used to install the
new lamp. Push lamp into hose just far enough to
hold bulb. Locate the socket slot and push firmly
up. Make sure not to let lamp fall into console base.
When bulb is seated, twist hose 1/4 turn to remove
from lamp.
(1) Place lamp in socket slot and push firmly up.
Make sure not to let lamp fall into console base.
(2) Install the console tray.
(3) Close console lid.
(4) Connect the battery negative cable.
CENTER CONSOLE LAMP
SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open console lid and remove tray.
(3) Using a flat bladed tool, pry up on the switch.
(4) Remove bulb from switch.
INSTALLATION
(1) Install bulb into switch.
(2) Push switch into console opening.
(3) Install tray and close lid.
(4) Connect battery negative cable.
CLUSTER ILLUMINATION
LAMPS
REMOVAL
(1) Remove the Instrument Cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Turn over cluster and expose the illumination
bulb sockets.
(3) Identify which bulb is defective and twist it out
of the cluster using a counterclockwise motion.
INSTALLATION
(1) Install the new bulb socket into the cluster
using a clockwise motion.
(2) Install the Instrument Cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
COURTESY LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick, pry lamp from door panel
(Fig. 1).
(3) Disconnect wire harness from the lamp.
(4) Remove lens from the lamp and remove bulb.
INSTALLATION
(1) Install bulb and lens to lamp.
(2) Reconnect wire harness to lamp.
(3) Press lamp into the door panel.
(4) Reconnect battery negative cable.
Fig. 1 COURTESY LAMP
1 - WIRE HARNESS
2 - COURTESY LAMP
RSLAMPS/LIGHTING - INTERIOR8L-21
LAMPS/LIGHTING - INTERIOR (Continued)