Removing gauge pod to install new warning light bulbs
Posted: Mon Jun 11, 2018 12:31 pm
Removing the 996 gauge pod sounds a lot more intimidating than it actually is.
Tools: A bit driver, Torx bits, spudgers/body panel tools/picks.
Parts: Cluster bulbs (available from Pelican; part link coming).
Using your picks or a soft-touch spudger, pry off the plastic cover on the left side of the cluster.
Use your picks/spudgers to remove the hazard light surround.
TIP: Mark the hazard switch so you'll know top from bottom later. I Sharpied mine @ the top.
Depress the retaining ears and carefully extract the hazard switch by pulling it TOWARD you. Do this carefully; if you torque the switch assembly too much, it pops apart and the tiny parts inside will disappear forever.
Once the switch is removed the harness for the hazard switch drops down out of the pod.
Remove both Torx bolts holding the pod to the dash.
CAREFULLY pry up the locking tabs on both ends of the bottom edge of the cluster. These tabs keep the gauge pod locked into the surround.
Remove and store the surround.
Roll the gauge pod forward so it rests on the steering colunm. Use a microfiber towel to protect the window if you're so inclined.
Roll down the driver window and cover the driver door with a towel or fender cover. Stand outside the car so you can see the three wiring harnesses that connect to the pod.
Depress the locking tab on the harness closest to you. With the tab depressed, swing the harness retaining clip upward to disengage the harness and unplug it from the cluster.
Repeat with the other two harness connectors. This photo shows the connector partially disengaged.
Getting the damned connectors to release is by far the hardest part of this project, especially if you're trying to do it by touch. Here's a close-up of how they work...
Once they're all disconnected, lift the pod out so you can continue working on it.
Use your bit driver to remove the problematic bulb(s) and replace with new parts. You may want to take a "before" picture showing the proper orientation of the properly installed bulbs. If you do not install and rotate the bulbs correctly, they may not connect correctly with the PCB inside the pod.
To reassemble, start with the innermost harness connector (the black one) and work outward so you have the most space and the best view. Again, standing outside looking in through the windshield is going to be a LOT easier than trying to do this all by feel from the driver seat.
Remember that you have to slide the hazard switch connecter back up from the bottom of the pod before inserting the hazard switch.
Be sure the switch is oriented properly (the mark you made during disassembly makes this easy).
PRO TIP: This would be a great time to reconnect the battery (if you disconnected it beforehand) and turn the key to the accessory position to ensure that all of the bulbs light up as expected...doing so at this point can save substantially on the overall amount of cursing involved with this project.
Tools: A bit driver, Torx bits, spudgers/body panel tools/picks.
Parts: Cluster bulbs (available from Pelican; part link coming).
Using your picks or a soft-touch spudger, pry off the plastic cover on the left side of the cluster.
Use your picks/spudgers to remove the hazard light surround.
TIP: Mark the hazard switch so you'll know top from bottom later. I Sharpied mine @ the top.
Depress the retaining ears and carefully extract the hazard switch by pulling it TOWARD you. Do this carefully; if you torque the switch assembly too much, it pops apart and the tiny parts inside will disappear forever.
Once the switch is removed the harness for the hazard switch drops down out of the pod.
Remove both Torx bolts holding the pod to the dash.
CAREFULLY pry up the locking tabs on both ends of the bottom edge of the cluster. These tabs keep the gauge pod locked into the surround.
Remove and store the surround.
Roll the gauge pod forward so it rests on the steering colunm. Use a microfiber towel to protect the window if you're so inclined.
Roll down the driver window and cover the driver door with a towel or fender cover. Stand outside the car so you can see the three wiring harnesses that connect to the pod.
Depress the locking tab on the harness closest to you. With the tab depressed, swing the harness retaining clip upward to disengage the harness and unplug it from the cluster.
Repeat with the other two harness connectors. This photo shows the connector partially disengaged.
Getting the damned connectors to release is by far the hardest part of this project, especially if you're trying to do it by touch. Here's a close-up of how they work...
- Detail.png (111.11 KiB) Viewed 3726 times
Once they're all disconnected, lift the pod out so you can continue working on it.
Use your bit driver to remove the problematic bulb(s) and replace with new parts. You may want to take a "before" picture showing the proper orientation of the properly installed bulbs. If you do not install and rotate the bulbs correctly, they may not connect correctly with the PCB inside the pod.
To reassemble, start with the innermost harness connector (the black one) and work outward so you have the most space and the best view. Again, standing outside looking in through the windshield is going to be a LOT easier than trying to do this all by feel from the driver seat.
Remember that you have to slide the hazard switch connecter back up from the bottom of the pod before inserting the hazard switch.
Be sure the switch is oriented properly (the mark you made during disassembly makes this easy).
PRO TIP: This would be a great time to reconnect the battery (if you disconnected it beforehand) and turn the key to the accessory position to ensure that all of the bulbs light up as expected...doing so at this point can save substantially on the overall amount of cursing involved with this project.