Spdrcer34
Explorer Addict
- Joined
- March 14, 2002
- Messages
- 3,873
- Reaction score
- 13
- City, State
- Bremerton, WA
- Year, Model & Trim Level
- 1992 Explorer XL
I searched EVERYWHERE for a comprehensive write-up on removing the ENTIRE dash assembly and I couldn't find a single one...Since it was my first time removing a dash from a 2nd Gen, I didn't know EXACTLY how difficult it would have been. I have removed NUMEROUS 1st Gen dashes, so I KINDA knew what I was getting into, but I wanted to know if there were any tricks I needed to know or anything like that, it was pretty straight forward. And believe it or not the 2nd Gen dash came out faster than a 1st Gen!
To get the dash out, you need to remove the A-pillar trim, and toe kick panels. If you don't know what those are, or how to do it, THIS project just may be over your head.
Okay....here it goes, complete with thumbnail pictures, just click on the picture and a full size version will appear in another window.
This job involves interaction with the airbag wiring, and controller. I CAN NOT EXPRESS ENOUGH how important it is to disconnect the battery!!!
This write-up also assumes that you have the Center Console removed already.
Lets start by removing the plastic panels that hide the mounting hardware:
I found the dash top panel is a little tricky to get out with out damaging anything...Insert a SMALL flat head screw driver, and pry up on the black plastic panel. You can see how the clips are oriented, and how close they are in these pictures:
The next part that comes off is the fuse panel cover:
And finally the panels under the steering column. The plastic panel uses a few 7mm anodized gold screws, and 2 more black screws in the Hood Release handle. The metal panel under the plastic utilizes a handful of 8mm (5/16") bolts.
\
Now that you can see under the dash, it's time to start disconnecting the plugs on the steering column. If it plugs in, un-plug it. EVERY WIRE that goes from the dash assembly to the Steering Column assembly disconnects within about 6" of eachother on the dash wiring harness. Once the steering column wiring is all unplugged, move over to the passenger side kick panel. There are a few more wires that need to be un-plugged over there, including the Fuel Pump Inertia Switch, and the Air Bag Controller Box.
Once you get the 'small' things unplugged, you need to move onto the 1 large connection on the far left of the firewall. From the Engine side of the firewall, you need to slide the Power Distribution Center up and away from it's mount to gain access to the 10mm
bolts that hold the 3 seperate medium connectors to the 1 large connector you saw from the interior. Once that is done, and the 3 connectors are moved out of the way, push a small flat head screwdrive in the Left and Right sides of each connector to release the clips from the sheetmetal. Once released, the connectors will fall towards the interior of the vehicle.
After you get everything unplugged, it's time to drop the column...
Now you can start un-bolting the dash assembly from the firewall.
Start with the 2 black 7mm screws nearest to the windshield
Then move onto the 13mm bolts along the windshield
Finally the 3 side bolts (13mm) can come off and you can pull the dash away from the firewall
With the dash pulled away, you can now disconnect the steering shaft, and shifter cable. Over on the passenger side you need to disconnect the Radio Antenna and unplug the Blend Door Servo Motor plug
Once you have the shaft and cable un-done, you will see 1 last large wiring connector that needs to be unplugged. It is held together by a single 10mm bolt.
If you have done it correctly, it will pull away from the firewall.
Now, with your dash out of the way, you can do a number of things...
Replace your Blend Door the HARD way
Replace your Heater Core
Change the Dash Wiring Harness over to add EATC/Information Center
I'm sure I will be continuing to update this write-up..but for now (11/28), I am done...
Ryan
To get the dash out, you need to remove the A-pillar trim, and toe kick panels. If you don't know what those are, or how to do it, THIS project just may be over your head.
Okay....here it goes, complete with thumbnail pictures, just click on the picture and a full size version will appear in another window.
This job involves interaction with the airbag wiring, and controller. I CAN NOT EXPRESS ENOUGH how important it is to disconnect the battery!!!
This write-up also assumes that you have the Center Console removed already.
Lets start by removing the plastic panels that hide the mounting hardware:
I found the dash top panel is a little tricky to get out with out damaging anything...Insert a SMALL flat head screw driver, and pry up on the black plastic panel. You can see how the clips are oriented, and how close they are in these pictures:
The next part that comes off is the fuse panel cover:
And finally the panels under the steering column. The plastic panel uses a few 7mm anodized gold screws, and 2 more black screws in the Hood Release handle. The metal panel under the plastic utilizes a handful of 8mm (5/16") bolts.
\
Now that you can see under the dash, it's time to start disconnecting the plugs on the steering column. If it plugs in, un-plug it. EVERY WIRE that goes from the dash assembly to the Steering Column assembly disconnects within about 6" of eachother on the dash wiring harness. Once the steering column wiring is all unplugged, move over to the passenger side kick panel. There are a few more wires that need to be un-plugged over there, including the Fuel Pump Inertia Switch, and the Air Bag Controller Box.
Once you get the 'small' things unplugged, you need to move onto the 1 large connection on the far left of the firewall. From the Engine side of the firewall, you need to slide the Power Distribution Center up and away from it's mount to gain access to the 10mm
bolts that hold the 3 seperate medium connectors to the 1 large connector you saw from the interior. Once that is done, and the 3 connectors are moved out of the way, push a small flat head screwdrive in the Left and Right sides of each connector to release the clips from the sheetmetal. Once released, the connectors will fall towards the interior of the vehicle.
After you get everything unplugged, it's time to drop the column...
Now you can start un-bolting the dash assembly from the firewall.
Start with the 2 black 7mm screws nearest to the windshield
Then move onto the 13mm bolts along the windshield
Finally the 3 side bolts (13mm) can come off and you can pull the dash away from the firewall
With the dash pulled away, you can now disconnect the steering shaft, and shifter cable. Over on the passenger side you need to disconnect the Radio Antenna and unplug the Blend Door Servo Motor plug
Once you have the shaft and cable un-done, you will see 1 last large wiring connector that needs to be unplugged. It is held together by a single 10mm bolt.
If you have done it correctly, it will pull away from the firewall.
Now, with your dash out of the way, you can do a number of things...
Replace your Blend Door the HARD way
Replace your Heater Core
Change the Dash Wiring Harness over to add EATC/Information Center
I'm sure I will be continuing to update this write-up..but for now (11/28), I am done...
Ryan