February 21, 2009
- Installed full gauge cluster with column shift indicator
- De-stripped the truck. A little rubbing compound and you cant even tell the stripe was there!
This is how I went about the XJ cluster in my 92 with electric speedo and column shift. I started to swap the new gauges into the old cluster housing, but the holes were not identical and did not feel like trying to figure everything out. I went about this with out having a clue what I was getting into. After All, I only bought the truck 3 weeks ago! This is what I did:
Factory Cluster still in the truck
1. Remove the fuel gauge from your factory gauge cluster and cut off the bottom. Use the top of the PRD3 1-2 opening as your cutting guide
2. Remove the PRD3 1-2 housing from your factory gauge cluster. Two screws and unhook the wire to the column.
3. Remove the cluster from the truck
Altering XJ donor Cluster
1. Remove the tach from your donor cluster, 3 or 4 screws on the back.
2. Notice: the bottom of the tach has two hole in each corner. Line up your PRD3 1-2 housing with those mysterious holes in the tach. Mark the tach where the PRD3 1-2 will be located.
3. Cut the Tach.
4. Place the lower portion of the original fuel gauge (the piece you cut in the beginning) behind the tach of of your donor gauges. Trim the PRD3 1-2 opening as necessary. You are essentially strengthening the tach to withstand the pressures of the column shift spring by doubling up the thickness of the tach.
5. Use 1" machine screws, nuts, and washers to fasten the PRD3 1-2 housing to the back side of the tach. I put the screw in from the back, through the PRD3 1-2 housing, added 2 nuts as spacers, through the tach, and fastened down with two nuts. The PRD3 1-2 housing is now securely positioned behind the tach. The plastic gauge bezel will cover up the end of the machine screws and nuts.
6. Trim any ribbing inside the donor gauges housing around the lower portion of the tach. Also, drill a big hole in the bottom of the donor housing between the speedo and tach. This is for the column shift wire to go through.
7. Test fit and check for clearances. The gas gauge might have capacitor on its circuit board. You may have to trim the PRD3 1-2 housing for clearance.
Installing the New XJ Cluster
1. Take the donor gauge cluster to your Jeep and get it plugged in (I would speculate holding off the the speedo cable at this time, the HO Jeeps do not have the speedo cable).
2. Fish the column shift wire through the hole you drilled and attach it to the proper place on the PRD3 1-2 housing. Push and hold the tach into position.
3. Twist the gauge cluster forward and down to gain access to the back. Reinstall the tach using the 3 or 4 screws through the back of the cluster housing. This is a royal pain, but possible with a small screw driver or bit driver. When doing this you will notice the gear indicator may move down to 1-2, this is simply because you are pulling on the column shift wire.
4. Rotate the cluster backward and attach the speedo cable if necessary.
5. Once stuck back in the dash, the PRD3 1-2 indicator should be in the park position and should be ready to go.
6. I plan on using some small black tubing to "frame" the PRD3 1-2 opening in an effort to clean up the cuts.
I am experimenting with 1/8" hard plastic vacuum line around the cut marks... It is still very rough, but I see potential!!!
Here you can see the end of the machine screw assembly described above. Once you get in there this should all make sense if you have never looked behind the dash bezel.
How it sits behind the bezel:
And lastly, what you see when driving. Using this method will put the indicator in a lower position than factory. This is magnified by my attempt to create a frame around the opening with the hard plastic vacuum line.
Yes, it still gets plenty of light from the tach lights to see at night.