Saturday, June 18, 2011

how to remove dash on 1998 chevy 1/2 ton pick up?

  • Open the doors on the Chevy and remove the end screws that hold the dash in place. These screws are on the ends of the dash and only accessible when the doors are open.

  • Remove the screw bolts underneath the dash.These bolts are typically in the driver and passenger foot wells. They may be underneath the dash in the footwells or on the front of the bottom of the dash.

  • Remove the defroster grill by prying it up with a trim removal tool.

  • Remove the screws underneath the defroster grill.

  • Pry the center bezel off the radio and HVAC control unit.

  • Remove the two screws on the underside of the cowl on the gauge cluster panel.

  • Remove the plastic protective cover from the gauge bezel. It should pull off now that you've removed the screws holding it in place.

  • Remove the four screws holding the gauge cluster to the dash and slide the cluster assembly forward.

  • Remove all of the plugs on the back of the gauge cluster and set the cluster aside.

  • Pry up the dashboard starting on the driver side of the dash. You may need to use the trim removal tool for this. Wedge the teeth of the tool underneath the dash and pry up on it until the retaining clips pop up. Work around the entire dash until all of the clips have been pried up.

  • Pull the dash out through the passenger side door with the help of an assistant.


  • The procedure is as follows:---
    You will need to remove the radio, to do this procedure:----
    Should be two screws above the speedometer cluster. They point upward.
    Remove them. Remove the hazard switch from the steering column. Start on the
    side where the lights are (drivers door side) pop the bezel away from the
    dash. It then pops away all the way over to the radio.

    Set Parking brake.
    Turn key on
    Move shifter to D(1) Low gear
    If it's tilt wheel, move wheel to it's lowest position
    Pull out drink holder
    Grasp top of dash panel firmly and pull.....should pop free
    Continue pulling until the whole thing is free.
    Unplug the headlight switch wires
    Unplug the cargo light wires
    Keep dash onto pass side floor
    Radio is removed by depressing 2 latches on either side of it and sliding
    the whole thing out
    Unplug antenna and speaker/power connector
    Remove radio, set it under one of the front wheels.

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    Instrument Panel and Pad

    REMOVAL & INSTALLATION




    CAUTION
    When replacing cluster components on the C/K Series trucks there are several steps which should be taken to avoid damage to Electrostatic Discharge Sensitive (ESD) parts. They are:



    Do not open the package until it is time to install the part
    Avoid touching the electrical terminals on the part
    Before removing the part from the package, ground the package to a known good ground on the truck
    Always touch a known good ground before handling the part. You should ground yourself occasionally while installing the part, especially after sliding across the seat, sitting down or walking a short distance

    1988-94 Models
    1. Disconnect the negative battery cable.
    2. Remove the center accessory plate by lifting from the bottom.
    3. Remove the bolt attaching the lower left compartment door to the carrier and remove the door.
    4. Remove the bolts holding the compartment to the carrier and remove the carrier.
    5. Open the ash tray assembly and remove the screws holding the tray to the carrier.
    6. Remove the tray assembly from the vehicle and disengage the wiring connector from the back of the assembly.
    7. Unfasten the screws retaining the bezel and remove the bezel.
    8. Disengage the headlamp switch and cargo lamp connector.
    9. Remove the radio control.
    10. Unfasten the screws retaining the heater control, disengage the wiring connector behind the heater control and remove the heater control.
    11. Unfasten the steering column filler panel and remove the filler panel.
    12. Disengage the shift indicator cable from behind the instrument cluster.
    13. Unfasten the instrument cluster retainers and remove the instrument cluster.
    14. Unfasten the air duct retainers and disconnect the air duct.
    15. Unfasten the instrument panel pod and trim retainers and remove the pod and trim.
    16. Remove the lower trim panels and the speaker covers.
    17. Remove the five upper carrier screws. There is one screw located under each speaker cover three located in the defroster vent grille.
    18. Disconnect the parking brake handle and cable from the rachet assembly.
    19. Unfasten the hood release handle retainers and remove the hood release handle.
    20. Unfasten the ALDL retaining screws and disengage the ALDL.
    21. Disengage the door jam switch and remove the fuse box cover.
    22. Remove the fasteners holding the carrier to the instrument panel support.
    23. Unfasten the nut from both sides of the steering column, lift the steering column up from the support studs and lower it.
    24. Remove the left and right kick pads by prying them off.
    25. Remove the snap clips and bolts from the left and right bracket mounted studs supporting the carrier.
    26. Remove the carrier and disengage the wiring harness from the back of the carrier.
    27. Disengage the connector to the instrument panel compartment lamp.
    28. Unfasten the bolts holding the A/C duct to the carrier and disconnect the A/C duct.
    29. Tag and disengage all electrical connections to the back of the carrier and remove the carrier from the vehicle.

    To install:
    1. Install the carrier in the cab and engage the wiring harness connectors and ground wire.
    2. Engage the door jam switches.
    3. Engage the A/C duct to the carrier and fasten the retainers.
    4. Engage the connector to the instrument panel compartment lamp.
    5. Install the carrier brackets to the body studs and the bolts through the body and carrier brackets. Tighten the bolts to 15 ft. lbs. (20 Nm).
    6. Install the clips over the body bracket studs.
    7. Install the upper carrier retaining fasteners and the fuse box cover.
    8. Engage the hood release cable, the ALDL connector and the parking brake cable.
    9. Connect the carrier to the instrument panel support and trim and install the pod and trim. Tighten the retainers.
    10. Install the lower left and right trim panels.
    11. Install the instrument cluster and tighten the fasteners.
    12. Lift the steering column onto the mounting studs and install the two nuts.
    13. Engage the shift indicator onto the steering column cover.
    14. Connect the heater wiring to the heater control and engage the heater control to the carrier.Tighten the fasteners.
    15. Engage the A/C duct to the pad and install the fasteners.
    16. Install the speaker cover and the left and right kick trim panels.
    17. Install the radio controls, engage the cargo lamp and headlamp electrical connectors.
    18. Install the bezel on the carrier and tighten the screws.
    19. Install the steering column filler panel and the ash tray assembly. Engage the electrical connectors to cigarette lighter and lamp.
    20. Install the strap around the ash tray assembly. Engage the assembly to the carrier and tighten the fasteners.
    21. Engage the instrument panel compartment to the right side carrier and tighten the fasteners.
    22. Install the compartment door and stop cables.
    23. Install the center accessory cover trim plate and connect the negative battery cable,

    1995-99 Models
    1. Disconnect the negative battery cable and disable the SIR system if equipped.
    2. Remove the three relay center bolts from inside the wheel opening and set aside.
    3. Disengage the cruise control harness, forward lamp harness, rear lamp harness, SIR system harness, relay center and unfasten the two screws retaining the convenience center to the cowl.
    4. Disengage the antenna lead-in and unfasten the steering shaft bolt.
    5. Remove the left and right hinge pillar trim panels and disconnect the brake release handle from the cable.
    6. Remove the lower bolster fasteners
      1. Unsnap the bolster.
      2. Twist the brake release cable to disengage.
      3. Disengage the lap cooler hose.

    7. Disconnect the reaction plate assembly and the tie bar.
    8. Disengage the 8-way column connector and the 48-way connector to gain access to the lower column nuts.
    9. Disconnect the shift cable (automatic transmission).
    10. Remove the steering column.
    11. Remove the shift levers
      1. Remove the transfer case lever by pulling straight up. 4WD models must be in 4-LO range.
      2. Manual transmission lever (if equipped).

    12. Remove the left and right instrument panel bolts.
    13. Remove the center support screws and the three upper instrument panel support screws.
    14. Remove the instrument panel from the cowl.
    15. Disconnect the parking brake release cable.
    16. Tag disengage the following electrical connectors (as necessary).

      DERM
      HVAC
      22-way engine harness
      Stoplamp switch
      VSS calibrator module
      Clutch or brake release switches
      Electronic accelerator (diesel)
      HVAC control cables (if equipped)

    17. Remove the instrument panel from the vehicle.

    To install:
    1. Install the instrument panel in the vehicle and rest it on the lower pivot studs.
    2. Connect the convenience center to the cowl and engage the lap cooler duct.
    3. Connect the DERM to the center instrument panel support and fasten the nut to the steering column support.
    4. Engage the parking brake cable and fasten the instrument panel pivot nuts.
    5. Install the instrument panel support nuts.
    6. Install the steering column and tighten the four nuts.
    7. Install the 48-way connector and screw built onto the steering column.
    8. Install the tie bar and tighten the fasteners.
    9. Install shift cable (automatic transmission) and the accelerator electrical connector (diesel).
    10. Install the knee bolster close out panel and the reaction plate. Tighten the fasteners.
    11. Install the shift knobs and the lap cooler hose.
    12. Engage the park brake cable and install the knee bolster trim.
    13. Install the bulkhead connector.
    14. Engage all the electrical connections in the engine compartment.
    15. Install the instrument panel storage compartment and the steering shaft and bolt.
    16. Enable the SIR system and connect the negative battery cable.
    --------------------------

    Instrument Cluster


    WARNING
    When replacing cluster components there are several steps which should be taken to avoid damage to Electrostatic Discharge Sensitive (EDS) parts. They are:



    Do not open the package until it is time to install the part
    Avoid touching the electrical terminals on the part
    Before removing the part from the package, ground the package to a known good ground on the truck
    Always touch a known good ground before handling the part. You should ground yourself occasionally while installing the part, especially after sliding across the seat, sitting down or walking a short distance

    REMOVAL & INSTALLATION



    1988-91 R/V Series

    See Figure 1



    Click image to see an enlarged view

    Fig. Fig. 1: Instrument cluster assembly-1988-98 R/V series

    1. Disconnect the negative battery cable.
    2. Remove the headlamp switch control knob.
    3. Remove the radio control knobs.
    4. Remove the steering column cover (4 screws).
    5. Unfasten the eight instrument bezel screws and remove instrument bezel.
    6. Reach under the dash, depress the speedometer cable tang, and remove the cable.
    7. Pull instrument cluster out just far enough to disconnect all lines and wires.
    8. Remove the cluster.

    To install:
    1. Install the cluster.
    2. Connect all lines and wires.
    3. Depress the speedometer cable tang, and reattach the cable.
    4. Install the instrument bezel.
    5. Install the steering column cover.
    6. Press on the radio control knobs.
    7. Install the headlamp switch control knob.
    8. Connect the negative battery cable.

    1988-91 C/K Models

    See Figures 2 and 3



    Click image to see an enlarged view

    Fig. Fig. 2: Instrument cluster bezel-1988-98 C/K series

    1. Disconnect the negative battery cable.
    2. Remove the radio control head.
    3. Remove the heater control panel.
    4. Momentarily ground the cluster assembly by jumping from the metal retaining plate to a good ground.
    5. On trucks with automatic transmission, remove the cluster trim plate.
    6. Remove the four cluster retaining screws.
    7. Carefully pull the cluster towards you until you can reach the electrical connector. Unplug the connector. Avoid touching the connector pins.

    To install:
    1. Carefully position the cluster until you can reach the electrical connector. Plug in the connector. Avoid touching the connector pins.
    2. Install the cluster retaining screws.
    3. Install the cluster trim plate.
    4. Install the heater control panel.
    5. Install the radio control head.
    6. Connect the negative battery cable.



    Click image to see an enlarged view

    Fig. Fig. 3: Instrument cluster assembly-1988-98 C/K series

    1992-94 C/K Models
    1. Disconnect the negative battery cable.
    2. Remove the instrument panel cluster bezel.
    3. Unplug the electrical connections for the headlamp switch and the dimmer control.
    4. Remove the radio control head.
    5. Remove the heater control panel. On air conditioned vehicles, disengage the A/C harness.
    6. Remove the cluster retaining screws.
    7. Disconnect the gear shift indicator cable from the steering column shift bowl.
    8. Carefully pull the cluster towards you until you can reach the electrical connector. Unplug the connector. Avoid touching the connector pins.
    9. If replacing the bulbs, turn the bulb assembly 1 / 2 turn to the left to remove.

    To install:
    1. Install the bulb assembly. Carefully position the cluster until you can reach the electrical connector. Plug in the connector. Avoid touching the connector pins.
    2. Install the cluster retaining screws.
    3. Connect the gear shift indicator cable.
    4. Install the heater control panel and A/C harness (if removed).
    5. Install the radio control head and any attach any electrical connections that were removed.
    6. Install the bezel.
    7. Connect the negative battery cable.

    1995-98 Models
    1. Disconnect the negative battery cable.
    2. If your vehicle is equipped with a tilt steering wheel, move the wheel to the lowest position. If the vehicle does not have a tilt wheel, it may be necessary to lower the column.
    3. Unfasten the eight clips that retain the instrument cluster bezel and remove the bezel. There are four clips on the top of the cluster bezel and four clips on the bottom of the cluster bezel.
    4. Unplug the electrical connections from the headlamp switch, dimmer control and any other accessory switches that would interfere cluster removal.
    5. Unfasten the four cluster retaining screws and remove the cluster making sure nothing contacts the circuit connections.
    6. If replacing the bulbs, turn the bulb assembly 1 / 2 turn to the left to remove.

    To install:
    1. Install the bulb assembly.
    2. Place the cluster into position without touching the connector pins. Install and tighten the cluster retainers.
    3. Attach the headlamp switch, dimmer control and any other accessory switches.
    4. Install the cluster bezel.
    5. return the steering wheel or column to its original position.
    6. Connect the negative battery cable.

    --------------

    Air Conditioning Components



    Repair or service of air conditioning components is not covered here, because of the risk of personal injury or death, and because of the legal ramifications of servicing these components without the proper EPA certification and experience. Cost, personal injury or death, environmental damage, and legal considerations (such as the fact that it is a federal crime to vent refrigerant into the atmosphere), dictate that the A/C components on your vehicle should be serviced only by a Motor Vehicle Air Conditioning (MVAC) trained, and EPA certified automotive technician.

    If your vehicle's A/C system uses R-12 refrigerant and is in need of recharging, the A/C system can be converted over to R-134a refrigerant (less environmentally harmful and expensive). Refer to Routine Maintenance for additional information on R-12 to R-134a conversions, and for additional considerations dealing with your vehicle's A/C system.


    -------------

    Console

    REMOVAL & INSTALLATION



    Center Console

    See Figure 1

    1. Remove the floor tray from the compartment.
    2. Remove the storage bin and the plugs covering the screws.
    3. Remove the screws and the storage compartment.
    4. Installation is the reverse of removal.



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the center console-1998 model shown

    Overhead Console

    See Figure 2

    1. Remove the console retaining screws.
    2. Disengage the console electrical connectors.
    3. Remove the console.
    4. Installation is the reverse of removal.



    Click image to see an enlarged view

    Fig. Fig. 2: Exploded view of the overhead console-1998 model shown

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