WARNING:
THIS IS MY PERSONAL EXPERIENCE AND IS NOT RECOMMENDED IF YOU CAN AFFORD TO PAY SOMEONE TO DO THIS FOR YOU. THIS REPLACEMENT PROCEDURE COMES FROM AN AMATEUR. I AM NOT A PROFESSIONAL TV REPAIRMAN!
DANGER WARNING:
THERE IS VERY HIGH VOLTAGE IN THE BACK OF A TV FROM ITS LARGE CAPACITORS. BE CAREFUL!!! THE MANY DELICATE CABLES AND CONNECTORS MUST BE RESPECTED! WHEN YOU OPEN THE BACK OF A DLP TV, AND DO A REPAIR, IT REQUIRES ATTENTION AND PAITENCE! THERE SHOULD BE NO RUSH! BE SURE ALL YOUR TOOLS ARE HANDY! TAKE PROPER PRECAUTIONS! AND, DO NOT DAMAGE THE EQUIPMENT! OTHERWISE, IT DEFEATS THE WHOLE PURPOSE OF MAKING THE REPAIR.
IF YOU ARE NOT ABLE TO DO THIS, THEN HIRE A TECHNICIAN TO DO IT FOR YOU!
Get Your Equipment.
Be sure you have…
- A moderately long Philips screwdriver.
- A leatherman or small pair of pliers.
- The Toshiba service manual.
- The ballast board (Toshiba Part Number: 23122468).
- Some tape or a marker to label the cables for when you need the right one.
- Patience… a lot.
Starting the Ballast Replacement.
1. UNPLUG THE TV! The TV needs to sit so you can easily get behind it. There should be at least 3 feet of working space behind the TV.
2. REMOVE THE LAMP ASSEMBLY.
3. Remove all the screws on the lower panel of the TV. Set the cover aside.
Toshiba 52HM84 Ballast Replacement
4. As you look to the rear of the TV, behind the fan and lamp assembly is the ballast board.
Toshiba 52HM84 Ballast Replacement 02 board
5. Remove the screws from the silver brace arm in the middle and the bronze screws that hold the light engine assembly. This brace attaches to the ribbon cable using a Zip tie; no need to cut the Zip tie. See the service manual if the following picture shows the screws fuzzy. Looking at the “light engine sled” will make it obvious.
Toshiba 52HM84 Ballast Replacement 03 light engine sled
6. Remove the bronze screw holding the plastic shield. The plastic shield angles down to the lamp. This screw is difficult to see when looking at the back of the TV. You have to look above the ribbon cable. The ribbon cable is attached to the back audio/visual (AV) board.
Toshiba 52HM84 Ballast Replacement 04 plastic shield ribbon cable audio visual board
7. With small pliers, squeeze the plastic nipples inward. Push the cable hangers out of the plastic shield. Be careful when removing the shield from the back of the TV. Once it is removed, set it aside.
Toshiba 52HM84 Ballast Replacement 05 plastic shield
8. Be careful here. Slowly remove the copper ribbon cable. This copper ribbon cable was the hardest to replace during reassembly, no joke. Whoever designed that ribbon cable needs a different job.
9. Remove the yellow, blue, and red connectors. Rhe connectors are different lengths and fits in only one receptacle, in case you forget.
Toshiba 52HM84 Ballast Replacement 06 copper ribbon cable
10. Once again, be careful with this step. Slowly remove the light engine assembly. There are 2 yellow leads that power the lamp assembly. Remove them, if needed.
For lamp assembly removal, first slide off the rubber footing. There is a very small clip. Push the clip back while pulling on the lead, to remove it. Once the leads are removed, be sure to label them with a marker or some tape. Mine were difficult to remove (I missed the clips under the rubber footing before publishing this), so I left them on. If you do not remove them, just be aware of the stress on the cable around the lens assembly. I removed the cables from the plastic thingie holding onto them and moved the yellow cables to the front of the lens assembly.
Toshiba 52HM84 Ballast Replacement 07 light engine assembly
11. Slowly remove the light engine sled. Place it to give you access to the ballast assembly.
Toshiba 52HM84 Ballast Replacement 08 light engine sled
12. Notice how dirty the ballast board is. Unscrew the two screws holding the ballast board.
Toshiba 52HM84 Ballast Replacement 09 ballast board screws
13. Remove the 2 connectors attached to the ballast board.
Toshiba 52HM84 Ballast Replacement 10 ballast board connectors
14. Carefully, push the plastic tabs holding the ballast board in place to the light engine assembly. Carefully, lift the ballast board to loosen it from the plastic tabs grip. There are two more tabs on the other side.
Finally, you can remove the ballast assembly entirely, so you can install the new board.
Toshiba 52HM84 Ballast Replacement 11 board light engine assembly
15. On the other side of the ballast assembly is the lamp connector. Unscrew the screws.
Toshiba 52HM84 Ballast Replacement 12 lamp connector
16. Carefully turn the lamp connector towards you to remove it. Remember the connector orientation because it needs to be the same to install the new board correctly.
Toshiba 52HM84 Ballast Replacement 13 lamp connector board
17. Install the new board and put everything back together. While everything is open, it might be a good idea to take some compressed air and blow all the dust out of there. Do not rush during reassembly. Be very, very, very careful connecting everything back together. It is mightily frustrating having to reopen the TV because a part was missing or something was not connected properly.
18. Be sure to put the back cover on the TV. Re-install the lamp assembly before connecting inputs and turning the TV on.
19. That’s it! If you were careful and thorough, you should be enjoying your Toshiba again. Plus, you probably saved several hundred dollars!
Congratulations!
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I had some Toshiba tech from a local dealer mess around with it, twice, for a total of 2 hours.
This may be hard to believe, but he seemed to know less than I did! He kept insisting the light engine was bad!
After dismissing him, I opened it up. Using this wonderful guide, the problem was fixed!
It took about 90 minutes (was very gentle during replacement) and your instructions were INVALUABLE!
This was my last try at repairing this before getting a new TV!!! The money you saved me… all I can say is THANKS!