Engine/Transmission (1994 - 1998) Help!

[SBozeman]

What a weekend! Just got back from a weekend on the beach and had several problems. Worst of which was getting stuck in the sand when my 4wd would not engage and got pulled out by a F150 4x4 belonging to the state police while Ford after Ford passed on either side. Still haven't figured out why it won't engage. Ideas?



After the sand incident on the way back to the campground the truck seemed a little sluggish and the TC would not lock up. Messed with the TPS and sprayed with contact cleaner. Works fine now. Still not sure what caused the sluggishness? Thought maybe sand in the drums





The thing I really would like to figure out is why my whole instrument panel failed on the way back home today. Nothing works: tach. speedo, oil press, temp, fuel gauge, etc. The odometer and trip meter flashes and does not advance. The ABS, Air Bag, and fuel low lights remain on. I hated driving home 5 hours without this stuff working, but at least I still had EGT, Boost and Trans temp gauges. Any help would be greatly appreciated. I would like to try a few things before I take it back to the dealer. No more warranty. Thanks

 

[SEmerson]

I had a bad connection with the plug on the trans that did the same thing. Check for frayed wires on top of the plug.

 

[SBozeman]

Instrument cluster assembly

Ran all the diagnostics from the service manual and it looks like I'll have to replace the instrument cluster assembly. It was replaced 2 1/2 yrs ago with the same exact symptoms. I called for a price quote from the dealer and was shocked at the $809. 00 price tag for a replacement. Ouch!



:--) Called every wrecking yard around here and no luck. Is there anyone who would know where I might be able to find a used or refurbished unit?

 

[mike_wilson]

I am having similar problems with my 2001 Dodge 2500 Diesel, although my check engine light is on and my odomenter reads no bus and my trip computer reads CCD. How did you determine it was the insturment cluster? What diagnostics did you run. Presently I don't have a service manual. Do I need to get one to run the diagnostics?

 

[scramblin]

Originally posted by mike_wilson

I am having similar problems with my 2001 Dodge 2500 Diesel, although my check engine light is on and my odomenter reads no bus and my trip computer reads CCD. How did you determine it was the insturment cluster? What diagnostics did you run. Presently I don't have a service manual. Do I need to get one to run the diagnostics?

I had an 01 wrangler with the same problem. The cluster and the plug were not making good contact. The dealer added dielectric (sp?) grease to the connection and the problem was solved.

 

[krs]

SBozeman,



I wouldn't be too hasty to start changing parts. Diagnotic routines in service manuals do not allow for the possibility of bad connections or the effect of moisture on connections.



It's rare to have a host of seemingly unrelated symptoms be the result of coincidental mass part failure. More likely one connection, or one important grounding point has either gotten wet, finally gotten oxidized too much, or both.



I don't know where your problem is, but, after all, you were at the beach.

 

[SBozeman]

This post was from July so the problem has since been fixed. I checked just about everything I could on my end. Tracing wires and checking grounds. Read every section that pertained to the instrument cluster in the service manual and exhaustive searches of the TDR discussion forums. In the end I could not find a solution so back to the dealer I went.



They also determined that the cluster needed to be replaced, again. I felt that this was such a rare problem that for this to be the third instrument cluster replacement they should pick up the bill and try to find out why it keeps happening. Unfortunately I could not get them to pay for it or do more trouble shooting, so out the door I went and in my $$ went to the tune of $906. 00 and that was after I talked them into a 10% discount.



Each new cluster has a 12 month warranty, so if this one shows any signs of failure, I'll have it back in there for replacement right away. I really hope I don't have to replace this thing every couple years. In the meantime I continue to look for wiring problems as I due routine MTX.

 

[SBozeman]

Mike



I'm not sure if doing the self diagnostics would be the same for you rig. I would have to look up the exact procedure when I get back in town, but for mine it involved turning the ignition key to ACC while holding down the odometer reset. The diagnostics test would start and display codes on the odometer. You just write down the codes and look them up in the service manual. The service manual tells you what the codes mean. You could also do a indicator test (fuel,oil,temp,tach,speedo. ,etc). That was the funny thing. The indicator test passed and showed all indicators working properly. After reading through the codes and consulting the service manual I concluded that it must have been a failure of the internal instrument cluster circuit board. And that's what the dealer also came up with. If you don't have a service manual I would recommend you get one. Use of it in conjunction with the TDR articles and discussion forums have been extremely helpful in solving and fixing problems with my rig. If you have the original owners manual you can order one using an order form or call the number on the back.

Good luck

Steve

 

[WadePatton]

Service manual # is 800 890 4038. They're about $100 and that is money WELL SPENT. If you're like me, you won't own a vehicle without the matching OEM service manual.

 

[Bob4x4]

Diagnostics

The service manual does not have much in the way of trouble shooting guides. What you need for that is either the body diagnostic or powertrain diagnostic manuals depending on what systems you are working on.



Bob

 

[krs]

"This post was from July. . "



LOL! I didn't notice that.



Nevertheless, I think that many times when there is a reoccuring electric/electronic problem it will eventually turn out to have been a result of an underlying weakness in the circuitry rather than an actual parts failure.