Clarion PU9868A Radio Repairs
Including Display Backlighting Bulb Replacement


Introduction
Removing Radio Front Cover
Removing Radio Body
Removing Front Panel from Radio Body
Bulb Removal and Replacement
Reassembly and Final Observations
Professional Repair Alternatives (covering LCD & other Radio, Tape, and CD Player Problems)

Introduction
The Clarion PU9868A radio and tape player in the 1995-1998 Range Rover (like that on any other vehicle) eventually needs servicing -- if nothing else the cassette mechanism is bound to wear out after a few years of use. The CD changer can also cease operation if its connector at the back of the radio unit comes loose. Another common problem is that, like other LCDs on the various dash displays in the Range Rover 4.0/4.6, the backlighting for the radio is provided by incandescent bulbs which eventually burn out, leaving the display dim or invisible. (In the case of the radio display, there are two bulbs, one on each side of the display, so if one fails you will still be able to see the display but one side of it will be very dim).

The illumination of the switches is provided by a further five sub-miniature bulbs. Note that these bulbs are NOT interchangeable with the LCD bulbs as they have a very different voltage/current rating. See the table at the end of this article for the ratings and Clarion part nos.

Ron Beckett has provided the following information and sequence of illustrations showing the procedure for removing the radio to access the rear connections for you to send the unit away for repairs (or, if you are sufficiently skilled and adventurous, to replace the backlighting bulbs).

Removing the Radio Front Trim/Cover
The first step is to remove the plastic cover panel that surrounds the main radio controls. It has a hole in it for the volume control knob, so there is no need to remove the volume control knob. Just insert some kind of hooked tool into the gap at each side of the radio cover panel and pull the panel off. Such tools (two required) are easy to make from a piece of thin aluminum stock. (See details in photos below and at top of page). The second time I did the operation, I had lost the "tool", but knowing how the panel is attached, had no trouble prying the cover off with an ordinary screwdriver.

Removing Radio Body
With the radio exposed you can insert two jeweler's screwdrivers (or nails) in the holes shown to disengage the clips holding the radio in place in the dash (see photo below). One of these clips is visible in the right hand photo below in the section on Removing Front Panel from Radio Body. They have to be pushed downwards just a bit to disengage. It takes a fairly firm pull and, if you manipulate the top clips while pulling, you will hear them disengage. I found sticking my fingers into the cassette tape opening gave me a good grip to pull the radio out. With the clips disengaged, you can pull the entire body of the radio out to disconnect the wiring harnesses.

At this point you are ready to send the radio out for repair. The usual procedure is to drop it off at the dealer -- they will charge you a preset fee and send it away for you. This is usually a slow and expensive process (I have used it twice), but fortunately there is now a far better alternative professional service available through Roverville Radio Repair Services who have lower charges and a 24 hour turnaround.

If you are not sending the radio away, but just want to check the CD changer plug connection that can sometimes fall out from the rear of the unit, you don't need to remove it entirely and disconnect the cables. In this case, it is easier to slide it out, and with the transmission lever in "Park", the body of the radio can be rested neatly on the shifter handle for support.  Note in the picture above the mounting screws (left and right of the radio) for the fascia switch pack have been removed -- this is not necessary for the radio removal operation. Ron was doing another job while the radio was out.)

Removing Front Panel from Radio Body
The following steps only apply if you are replacing the bulbs

The volume knob now has to be pulled off. Then, after unclipping the side clips (two on one end, one on the other), you have to tilt the bottom of the panel slightly out so that the two top surface retaining lugs are easier to release. Ron advises not pushing down on them, as they will break. (I found some fiddling with one of them was needed to get the front panel to release -- see below).

After tilting the front panel slightly it can be carefully pulled away from the main body of the radio. You might have to give the top clips a bit of help with a screwdriver though. The panel cannot be tilted very much because of the guides for the side clips, and it is a little stiff to pull off as there is a multiplug that is being disconnected at the same time (white plug in lower right of photo below). This forms the electrical connections between the front panel and the rest of the radio.

With the front panel off, you can now see the back of it (photo below) and the location of not only the two LCD backlight bulbs but the five other bulbs which illuminate the radio controls.

Bulb Removal and Replacement

With the back of the panel accessible, the LCD backlight bulbs can be exposed by peeling back the black self-adhesive covers that protect them (see photo above left). The miniature bulbs have no proper holder, but they have a silicone cap which surrounds the globe and locks into the PCB (photo above right).  The flying leads are simply soldered to the printed circuit board.  To unsolder the old bulb and resolder the new one, use a small soldering iron that does not generate too much heat and is intended for electronic work, otherwise you might accidentally unsolder other connections on the board or damage the PCB. The two LCD back-lighting bulbs are 8 volt 105mA whilst the five switch illumination bulbs are 14v 40mA. Do not interchange them. The 8 volt LCD backlight bulb, if fitted to a switch illumination location, will be operating from too high a voltage and will either burn out or melt the plastic switches - or both.

Reassembly and Final Observations
Assembly is the reverse of removal.

For those with the necessary expertise to replace them, we have included the part numbers for the LCD display and the bulbs. The display used has a propensity to fade after about 10-15 years. Fortunately, it is available from Clarion Service Centers or Roverville Radio and is quite reasonably priced.

Note: We do not recommend LCD replacement by persons with little experience of electronic repairs. Removal of the metal LCD surround/clamp is not a job to be attempted unless you know what you are doing. Ron was an electronics tech with sufficient experience to undertake this delicate task. Leave this for the experts.

Professional Repair Alternatives
John and Tom at Roverville Radio observe that people attempting radio repairs with little to no experience in such fine/micro electronics tend to mess components up along the way... they have to fix them after you've tried and it makes it harder and more costly in the long run!  Roverville warns "Note with respect to the info above: the button lamps are a different voltage from the LCD illumination, DO NOT INTERCHANGE THEM!!!! YOU'LL MELT THE FACE BUTTONS and also note the green filters are usually melted on so these cannot be reused.  You have to use correctly specified lamps (we do sell them and other parts too, including entire new faces)." (I should know, because I tried it myself, botched it up and had to send my unit in for a proper repair!).

The following information is provided on Roverville's services for the benefit of RangeRovers.net readers. Roverville have kindly offered to help sponsor this website, so if you contact them, please make sure you mention RangeRovers.net!!

Roverville - Radio Repair, USA & UK
Independent Land Rover Stereo Repairs, Sales & Service
Website: www.roverville.us

John of Roverville - Radio personally owns eight Land Rovers and is an active member of Texas Rovers Land Rover Owners Club

Roverville - Radio provide top quality repair work with all genuine factory parts at a fraction of Dealer middle-man prices and delaying turnaround time.  Most dealers do not offer radio repair service...  they'd sooner sell you a new one for a few $1,000 or £1,000.  If you hear "It's a fried/dead/no good unit", send Roverville an e-mail... they can revive it back to perfection. Usual Repair price is US$185, depending on the model unit you have. This includes everything right down to return shipping. The sooner you send in your unit the sooner you'll be enjoying your music and chat shows again.  They carry the full line of Rover units, all fully serviced perfectly and with warranty for exchange if you prefer not to wait for repairs.  This method costs a little more but you have a unit shipped to you on the day yours arrives at Roverville, though usual repair time is about 2 days + shipping.

They also repair units for the dealers world-wide and lucky individuals like you reading this - those that prefer not to wait the 2-3 months it takes most other repair shops.  Bottom line, they know these units inside and out!  They specialize in Land Rover units only. That's what they do at Roverville Radio - Repair!

Roverville - Radio also buy any Rover stereo equipment, CD changers, woofers, wiring harnesses, amps, and speakers, in working or non-working condition with or without code.  All units are professionally tested and reconditioned to like new prior to resale.  Payment for used equipment will be made once received by Roverville.

Unfortunately, Roverville have found that many inquiries are from owners simply wanting free advice; they do like to help, but cannot spend all their time just helping out on the phone -- though if you are genuinely interested in professional repair or exchange services you should definitely contact them in the USA or UK via http://www.roverville.us.  They will reply with helpful "easy for anyone to follow" removal instructions, pictures, etc., so you can remove the radio/CD, etc., yourself, saving you at least $100 that a dealer would charge you.

When you send them an e-mail please explain your stereo's issues as best you can! Also state the year and model of your Rover. Thanks!

I can personally vouch for their outstanding service, having used it myself. It was amazing having a one-day turnaround rather than the typical wait of weeks or months through the dealer (which I have also experienced twice before).