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Some pads use 10mm nuts, but most use 9mm. Some have a nut between the radio & cluster.
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TSB 92-25-09 Popping/Cracking from Dash Pad during Cooling
Publication Date: DECEMBER 2, 1992
LIGHT TRUCK: 1992-93 F SUPER DUTY, F-150-350 SERIES
ISSUE: A sharp "popping/cracking" noise may be heard from the instrument panel. This condition is most noticable on vehicles in warmer climates. The "popping/cracking" is caused by the rubbing of the mating surfaces between the instrument panel and the instrument pad when they are cooled, such as when air conditioning is being used.
ACTION: Eliminate the "popping/cracking" noise by inserting insulating material between the instrument panel and instrument pad. Refer to the following procedure for service details.
SERVICE PROCEDURE
1. Remove the radio.
2. Open and remove the glove box door assembly.
3. Remove the seven (7) nuts retaining the pad assembly to the instrument panel.
NOTE: THE PAD ASSEMBLY MAY BE DIFFICULT TO REMOVE BECAUSE THE PAINT MAY ACT LIKE AN ADHESIVE.
4. Remove the paint residue and other contaminants from the back of the pad assembly.
5. Install insulating tape at eight places on the instrument panel. Refer to figure for locations of tape.
6. Position pad on instrument panel.
7. Install a 3/16" I.D. X 5/8" O.D. X 1/32" to 1/16" thick, zinc coated washer (which can be obtained locally) and a nut on each stud. Hand tighten until snug.
CAUTION: DO NOT USE POWER TOOLS.
8. Install the radio and glove box assembly.
Procure locally, seven (7) 3/16" I.D. X 5/8" O.D. X 1/32" to 1/16" thick, flat steel washers. The washers must be ZINC coated, not oil coated.
Procure polyethylene tape locally. One roll, 2" wide X 72" long, repairs about eight vehicles and costs $8.09 per roll.
Procure tape from:
Walco Corporation
Adhesive Tapes Division
P.O. Box 9
1652 East Sutter Road
Glenshaw. PA. 15116
Attn: Ron Ruddock
Telephone: (412) 486-4400
Fax: (412) 486-6884
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under 12 Months/12,000 Miles
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OPERATION DESCRIPTION TIME
922509A Install Insulating Tape 0.6 Hr.
Instead of flock tape, almost anything that will allow slight movement without noise will work - even dry paper or plastic, as Ford used.
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Cluster Bezel Repairs
It's common for the clips across the top snap off their mounting posts, but the posts are hollow, so it's fairly easy to install a *****. The hardest part is getting the final 1/4 turn on the ***** so the clip stays tight.
It's even more common for the ***** holes behind the trim strips to break out, but it's easier to repair them. I used this plumber's strap to hang some hardware for powdercoating, which is why it's black. But since it'll be totally hidden, plain strap is just as good. Even if the holes haven't cracked yet, this mod will prevent them from ever breaking.
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http://www.supermotors.net/registry/media/820786]
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