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Home >> Mercury >> 1997 >> Cougar/XR7 V8-4.6L VIN W >> Repair and Diagnosis >> Instrument Panel, Gauges and Warning Indicators >> Dashboard / Instrument Panel >> Service and Repair >> Instrument Panel - Replacement >> Disassembly and Assembly

Disassembly and Assembly

DISASSEMBLY







1. Remove screws holding the instrument panel finish panel and gently pry off.
2. Remove four instrument cluster retaining screws. (Do not remove screws from the instrument cluster main lens and instrument cluster mask).
3. Slide the instrument cluster to the right of the instrument panel opening and unhook the instrument panel harness from the back of the instrument cluster.
4. Remove the instrument cluster from the instrument panel.
5. Insert Radio Removing Tool T87P-19061-A in retaining clip of A/C control.
6. Apply a side load away from the control to disengage clips.












7. Pull the A/C control from the instrument panel opening and disconnect the wire connectors from the control assembly.
8. Disconnect the vacuum harness.
9. Install Radio Removing Tool T87P-19061-A into radio face plate. Push tools in approximately 25.4 mm (1 inch) to release retaining clips.

CAUTION: Do not use excessive force when installing Radio Removing Tool T87P-19061-A, as this will damage retaining clips, making radio chassis removal difficult and may cause damage.

10. Apply a slight spreading force on tools and pull radio chassis out of instrument panel.







11. Disconnect the wiring connectors and antenna cable and remove the radio chassis.
12. Remove center instrument panel finish panel.
13. Remove two screws retaining windshield defroster hose nozzle to top of instrument panel. Remove windshield defroster hose nozzle from the instrument panel.
14. Remove two retaining screws from RH A/C side window demister and hose. Remove A/C side window demister and hose from the instrument panel.
15. Remove the retaining screw for LH A/C side window demister and hose and remove LH A/C side window demister and hose.
16. Remove strap holding A/C side window demister and hose and wiring to the heater air plenum chamber.
17. Unscrew flexible A/C side window demister and hose from the plenum center register assembly and remove RH and LH A/C side window demister and hose.







18. Remove two screws retaining RH A/C evaporator register duct to instrument panel and remove RH A/C evaporator register duct.
19. Remove screw retaining heater air plenum chamber assembly to instrument panel.
20. Remove heater air plenum chamber.
21. Remove two vertically-driven bolts on both sides of bottom of passenger side air bag module.
22. Remove two fore-aft driven bolts that attach air bag tabs to instrument panel steel.
23. Gently push passenger side air bag module from back of instrument panel opening enough to allow access to electrical connector.
24. Disconnect electrical connector.







25. Remove passenger side air bag module.

WARNING: PLACE AIR BAG MODULE ON BENCH WITH TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

26. Remove headlamp switch knob by pulling off.
27. Remove the hex nut retaining the finish panel to the headlamp switch and remove panel.
28. Remove two screws retaining the headlamp switch to the instrument panel.







29. Pull headlamp switch away from instrument panel far enough to disconnect the wiring.
30. Remove screws retaining light switch rheostat resistor.
31. Disconnect electrical connector and remove light switch rheostat resistor.
32. Disengage harness from all locators, straps or clips as necessary, including ground wire eyelets. Remove harness from instrument panel.

ASSEMBLY
1. Install instrument panel wiring harness and secure to instrument panel reinforcement with all locators, straps or clips including ground wire eyelets.







2. Install headlamp switch and light switch rheostat resistor.
3. Connect electrical connector to passenger side air bag module and position passenger side air bag module in instrument panel.
4. Install two fore-aft driven bolts that attach air bag tabs to instrument panel steel. Tighten bolts to 7-11 Nm (62-97 Lb-In).







5. Install two vertically-driven bolts on both sides of bottom of passenger side air bag module. Tighten bolts to 7-11 Nm (62-97 Lb-In).
6. Position heater air plenum chamber and A/C evaporator register duct on the instrument panel and install screws.
7. Position windshield defroster hose nozzle on heater air plenum chamber. Then install two screws to retain the windshield defroster hose nozzle to instrument panel at defroster opening.







8. Install A/C evaporator register ducts with two retaining screws.
9. Install center instrument panel finish panel.
10. Connect wiring connectors and antenna cable to radio chassis.







11. Slide radio chassis into instrument panel, making sure that rear radio chassis support is engaged on lower support rail.
12. Push radio chassis inward until retaining clips are fully engaged.
13. Connect the wire connectors and the vacuum harness.












14. Position the A/C control in the instrument panel opening. Engage it in the track in the instrument panel and push it in until it latches firmly in place.
15. Connect the instrument panel wire harness to the back of the instrument cluster.
16. Install instrument cluster to the instrument panel with four retaining screws.
17. Install instrument panel finish panel.
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