Ford SuperDuty Battery Saver Relay Cluster Repair
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- Опубликовано: 21 авг 2024
- In this video I go over common issues with the Ford Instrument Cluster that causes intermittent power, power windows, dome light and radio.
This is part of the battery saver relay circuit found in the diesel F-250, F-350, F-450, F-550, & Excursion SuperDuty.
This video covers both 2002 to 2004 and 2005 to 2007 styles.
My email: 1mr.repairman@gmail.com
email 1mr.repairman@gmail.com Correction, dome light is included on the battery saver circuit not power door locks.
Try rose alloy for desoldering chip packages .. brandname chipquick. It mixes with the tin and stays molten long enough to heat all sides and allows parts to just magically lift away. I use it with my smd repairs. No worrying about overheating the traces. Not saying you needed it for this project but removing cpu/mcp and roms.. easy.. seen you do these in the past
@@Astinsan I actually have some chipquick low melt solder and I've tried it. It never really stuck with me, I just hot air chips off. I have a nice assortment of nozzle tips.
@@jeffescortlx maybe gauge cluster boards are more forgiving than a macbook logic boards. Multilayer boards do weird things without a preheat tray. The stuff is a life saver in a pinch
@@Astinsan maybe. The only time I need to pull out the pre-heater is if I'm going to remove a microprocessor.
@@jeffescortlx I would imagine some of those are more micro controlers... cpu’s with a small program inserted. You ever have to jtag or canbus the units?
Thank you Sir! I just fixed my F550 by following your instructions. Its so satisfying to solve a problem. Your advice was perfect.
Love the shipping department
A reliable shipping department is a rare find!
I think they are only in on it for the benefits.
So I guess if I use your service I should include cat treats with my cluster to insure your shipping department returns my cluster promptly?
I am havening problems with my 2003 cluster and would like to see more on repairing it. First ford cluster repair I saw. Thanks
I would really like to see the 03 battery saver relay circuit repair! I am subscribed! Thanks for the video
tks for the video I was thinking about doing repair myself but now I can see it would be way beyond my skill level.
Excellent work sir. Just the right amount commentary, and skilled solder work. I am subscribed.
Keep it up!
Happy Holidays to you and the crew. Thanks for the video. It will save time on the initial truck diagnostic for sure. I didn't know the battery saver was in the cluster.
Thanks & Happy Holidays!!!!
Not sure if someone commented yet already, but that 1200 ohm resistor (looks like 3216 size (or 1206 in inches)) you solder at the 3m10s mark, you heated up one side and the resistor moved (indicating the south end had a broken solder joint)
Looks like I'll be inspecting a 2006 F250 SuperDuty cluster that's intermittently going out. Thanks for the informative video.
Nice thanks for uploading this. My 2002 battery saver circuit is problematic. I've been thinking of sending the cluster off for repair but I may try it myself now
You have a microscope and hot air station?
@@jeffescortlx im an electrical engineer and I've got a USB microscope but no air station just a good soldering iron. I fixed the HVAC module in my corvette earlier this year that had cracked solder joints that made the screen not come on. Those parts are a lot bigger than in the Ford cluster it seems...
Great video ! Been chasing an intermittent on an 05 f250 will be sending you the Custer's cluster
Man am I glad to see these videos popping back up. I don’t know what happened but your channel kinda dropped off my RUclips radar! Happy holidays man! I have a quick question have you messed with 2012 Cruze cluster? Every now and then when I’m warming up my car. The rpm and mph will go crazy and lock my doors. Saw somewhere that it was a cluster issue. Wondering if you have ever heard of that?
It's possible, but I'm not familiar with that particular cluster/year.
DAMN! The one I need is the one that didn't record! 2002.
Thanks for the help jeff
0:44 Hi cats! 🐈 🐈
Thanks for sharing your expertise 👍
Those cats are my favorite
Merry Xmas To You JeffEscortlx!!!
refreshing to find skilled labor.
Another great video! ( and cats too! ) I take it the gel substance you are using is flux? If so what brand?
AMTECH it's great. I purchase it directly from Louis Rossman to make sure it's genuine.
I must be missing something because no email shows up at the end!
Thanks for returning a response!
It's in the video description, just below the video.
Awesome work man! I'm going to leave this to the pros lol About to ship mine off to Circuit Board Medics. Is that who you'd recommend?
Circuit board medics does good work.
Would love to see a reflow on the battery saver relay for the 2002-04 models video when you have a chance. Possibly an overhead trip computer reflow too for those years if you’re bored 😂
8:43
@jeffescortlx how to contact you
Awesome job great content!🎉
Ahh crackus jointicus, rub some oil of ulay into them :)
Vibration and temperature expansion then contraction damage.
Blanket soldering is usefull for those times where a section always plays up.
One type of c.b radio that i used to repair always failed in the vco/synth section.
And i do mean ALWAYS, blanket soldering worked every time.
Loverly cats, no bad joints on them ha ha :-D
Wow sir, that is fascinating. Great Video and skills. I may need to hire you for a fix on my 02 Ford Excursion. It will run however there is no display and gauges read zeros, no radio display but radio was still working.
Can you describe the brake warn LED & buzzer circuit? I have chased the problem down to the circuit board but I cannot find the actual schematic anywhere. In chasing the traces it appears the connections are okay. I will reflow them, as you suggest, but an understanding of how the grounding of the brake circuit via J3/C220c [~pin9/10 and/or J2/J220b [pin11] causes the LED [D32] to illuminate? It appears to be similar in configuration to the other warning/dummy lights and it would be helpful to understand [much] better how the voltage and logic flow.
Ford instrument clusters have a reputation of fracture solder joints at a resistor that cause the brake light to illuminate when it should not.
@@jeffescortlx Do you recall which resistor?
@@bobbyshaftoeI think it's labeled [801] it's a fairly large package. I don't remember going off of memory but if I saw the board I'd recognize it.
Unfortunately there is no 801 :-/ I [PAINSTAKINGLY] inhaled lead fumes for a good couple hours while I reflowed *all* components on the board (both sides) including the IC's. Amazingly, I didn't break anything! Unfortunately...this didn't fix the Brake light+dinger situation.
Is there any chance you can think of which resistor that might be? Or, if it's some kind of input voltage biasing resistor? I suppose it must be connected directly to one of the input pins (either the parking brake pin, the brake fluid level pin, or the pin that goes out to the 'generic sensors' box (I forget the name of it, but it must be the one that presents the OBD).
Because the LED circuit's biasing resistors are downstream of the IC(6) which also (correctly) signals the chime/dinger to fire off (THAT gets annoying, btw) I am pretty sure that 'downstream of IC6' circuit is good to go.
Thanks again for your advice and vid! @@jeffescortlx
@@bobbyshaftoeit's a fairly large SMD resistor, not too far from the connector, just don't remember if it's the left or right side.
Are you sure the brake fluid sensor and e-brake switch are not causing the issue?
Jeff, would you mind doing a video on the 04-05 Ford Explorer sport-trac? I come across a few of these and would like to know common trouble spots. Thanks and keep up the awesome vids!
The shipping department...lazy bunch a.....awww nevermind, they looked so comfy sleeping in the box!
I have a 2003 Excursion, and the one thing you forgot to record was exactly what I needed. Did you ever make another video detailing those repairs?
Which part of the process are you looking for help with?
@@jeffescortlx I'm looking for a step by step on how to fix it myself, as you showed with the other gauge cluster. I have the skills and the tools, I just need to know where the common points are that need solder added.
@@hershelr.sullivaniii7139but I did show step by step directions for that style. It's in the second half of this video.
F250 super duty, randomly the speedometer quits working. It's my father inlaw's vehicle. I looked at the cluster and resoldered the main pins from the plugs but didn't go much further about 2 years ago. I saw where the signal was actually sent from the abs module. With no more information and I never saw it quit myself, I told him I wasn't sure what to do. Ford replaced the cluster for about 900$ about a year later it started happening again. Any ideas?
It depends. If it's ONLY the MPH acting up, then it's maybe not the cluster at all, but a incoming signal issue. But if the entire cluster is intermittent than it probably has the issues covered in this video.
Great video ! 👍
Awhile back I saw you reinstall the miles back into a cluster. You posted a link in AMAZON about the machine/tools you used.
Could you please do that again. Thanks
Have the same shipping department issue. Any open box in the house is fair game! Hope you and the family have a wonderful Christmas and New Year jeffexortix.
Thanks you to!
on our e450 ford fleet usely it alway the fuel gauge that screw up .when you do the gauge test swip the work fine.but often they it indicate empty on 2007 .would it be just soldering or resistor gone bad.we do not fix cluster at work we buy them at ford dealer
If the gauge sweep test is fine, and if the sending unit is working fine, than yes it's probably just a fractured joint. As you can tell from the microscope footage about 3 resistors were fractured.
great work once again Jeff. There is not a lot on Fords out on the web so I am glad you shared that with us. I would love to see you do a 2005 Ford Explorer Sportrac as I see many failures with them that is very similar to these. Intermittent and loss communication with doors and other things within the truck. Would you please do one of these because I know you will be spot on with the repair! Thanks Jeff and Merry Christmas to you and your Family! James
I believe with the sportrac the truck wont even start when the cluster goes out.
Hello! Great info! I'm wondering if you could share which wires need power and ground to get the cluster to light up on a bench? Have a pinout diagram and have put power and ground to the circuits that are obvious but still no power to cluster. Cluster worked great before truck was tore down
You have to apply power to not only the continuous 12 volt supply but all the ignition circuits too if you want it to fully turn on.
Jeff your da man in don't work on them myself but for some reason it enjoy watching you but it do have a question do you know anyone that works on automotive hvac head controls.i have a intermittent fan problems already installed new blower motor and resister
How does the motor connector look? Typically the motor connector is the lower part the the blower box and that where all the moisture drips that is collected.
@@jeffescortlx they have been checked and preped for good measure lol
Great video , I believe I’m having an intermittent issue with mine . I replaced a bad relay in my junction box thinking that was my problem . But issues are still present .
Only thing my truck does different is the headlights and interior lights and bell on as soon as I hook up battery? Could that battery saver relay be my issue ?
With these years of Super Dutys, the instrument cluster does not have any control over the headlights.
It looks like with the 2006 design there is a wire on the instrument cluster labeled headlamp switch tail lamp and side markers A7 pin.
Thanks for information.
VERY GOOD JOB
2005 Ford Excursion
I replaced the lights in my cluster with LEDs and it worked great for awhile. I then went and switched my done lights to LEDs. Now my windows, radio, and main and read dome lights dont work. Power locks work and middle row lights work.
Does this sound like the battery saver relay in the cluster??
With this year range, typically the instrument cluster itself will be dead along with the radio/windows. You might have just accidentally popped a fuse.
on the 06 model what wires are supposed to be powered up to make it work i’m wanting to splice in a light in the harness to see if the problem is the truck or the cluster that is bad
With the older style cluster is it safe to swap out the bulbs and put in LEDs? I’ve had issues in the past where after putting in LED bulbs they never seem to turn off completely.
Jeff i have one of these that the fuel gauge doesnt work on. I can put a 100ohm resistor across the sending pins and nothing changes. Wondering if youve seen this issue. Ive done the tupical mcu and component reflow. No change
Follow the sending unit traces on the cluster PCB, there will be a couple resistors not too far from the connector that are known to fracture. They might be colored blue, but I could be wrong, I'm just going off of memory.
If the delay accessory relay goes on intermittently with the key out, could this be a cluster issue (2003 excursion)? Never had the gauges go out. Thanks
Kind of unrelated but I have a buddies O2 super duty in right now that is not charging even though it has a brand new alternator. Also the cluster does not work at all and the radio decided to turn on about five minutes after I was checking fuses with the key on. I’m wondering if something within the cluster is causing all of these issues may try to grab a junkyard one in hopes that it’s still operational. Also has .14 amp draw and when I remove the battery saver fuse it drops to near 0.
The cluster could be responsible for some of those problems.
Don't throw out the original cluster until your 100% sure you have the proper replacement. Different trim models have different clusters, plus the odometer value is stored in the cluster. So if you toss in a high mileage junk yard cluster, you could devalue the vehicle by thousands.
What temp are you around when working on these joints?
I change mine out with a used one and everything works fine but the mileage is higher my old cluster was moving around too bad didn't know how fast I was going sometimes and my gas didn't work G35 Infiniti 2006 sedan is there anything I can do about the mileage
hi Jeff! my name is dan and I have a 06 f350 6l with dash problems! do you repair them if so, could I send you mine?
Yes
@@jeffescortlx i could mail it out today! Do you have an address I could ship to?
@@dantreeman9870 my email address is listed at the bottom of the video description.
I know this was a year or so but your video was one of the best ever do you still repair if so how can I get my 2006 cluster to u if not can you tell me were to send it I'm from Kansas City MO. Thx in advance
2006 f350 turbocharged super duty 6.0
@@kenniemouser2090 yes I'm still repairing these clusters. My email address is available at the bottom of this video description.
I have an 02 F250 cluster I was working on and found the R74 resistor broke off but I have no idea what ohm rating it is
Sorry I don't have a board here to reference. The resistor end is completly broken off?
does the K115 Battery saver relay in the 2002's go bad or is it the solder joint?
I have an 03 F250 XL. I can’t seem to find any information if it has a battery saver relay considering the only thing power on my truck is the radio and air conditioning lol. No power locks windows or mirrors
Yes 2002 to 07 super dutys run the radio power through the cluster.
Is there a way to reset the needles when they are outta wack? When I reflowed IC6 it apparently lost the needle location memory.
If you're sure that the needle has been reseated in the correct position, and if the stepper motor isn't reading correctly, more than likely there is either a short or a break in the connection for that stepper motor.
@@jeffescortlxhmmm. Its all of them. *they were all functioning fine prior to reflowing ic6. I removed ic6; cleaned the pads, reflowed. All the needs are outta wack.. but they all move correctly [speedo goes up when speeding up, tach goes up when accelerating, fuel need drops with consumption ..etc.
@@bobbyshaftoe45it might just be a matter of reseating the needles back into the same orientation with the stepper motor shaft prior to the first needle removal.
@@jeffescortlx I just removed the clear cover..with everything plugged in.. then I just popped the needles and put them where they needed to be :-)
I have a 2005 Super Duty V10 XL Manual Trans.No power door locks or windows (manual).The radio, especially in cold weather, takes some time to come on when starting out for the day.Looks like you have the fix.Correct?
Probably could be yes
Very interesting video. Thank you. The fuel gauge associated with my 2006 F250 6.0 has been progressively getting more inaccurate showing a half tank when empty. Could this issue be related to the issues you illustrate here and would the repair be similar? Could I send you my instrument cluster for repair?
Battery saver circuit is not related to the fuel gauge operation. But it could be a internal cluster issue. Could also be a problem at the sending unit. I'd recommend to run a gauge sweep test. I have a video on that if you need.
That's your meter in tank sends faulty information.
@@jeffescortlx How much for this type of job?
@@slavikonufriychuk3485 for quotes I can be reached through email, available in the video description.
Do you need a bcm to test the fords like you need for a gm cluster?
For the clusters I work on, neither need a BCM to test. With the Ford's it's all built into the cluster, can be started through the trip button. With chevy a scan tool can talk directly to the cluster and trigger a test.
Ever see the dome light dosent shut off, no door ajar warning, and dinger goes off when the door is open?
Quick question, on the all black “XL-XLT” 2005-2007 cluster and the silver and black “lariat” cluster. Could I find a lariat cluster and just put that skin on my XLT? Then put it back together and all should work properly correct??
If everything matches up I believe so. I've never tried. Sometimes the prnd321 display changes.
Jeff, Do you have any experience with can-bus sniffing? Looking to turn my 04 Cluster into a relay module, which resends can-bus data(sniffed, and ready to assign) to another newer cluster using something as simple as Arduino.
I'm sorry I do not. But I can recommend contacting Matt from the channel fixed until broken. This sounds like something he would have experience with.
I've resoldered all the components inside it worked well for 2 days and now its doing it again witch solder points should I focus on
I have the 05 with the turbo boost
@@bryantvance1302 this video covers the common problem areas. If it still isn't working correctly you might need to send it out.
The shipping department says talk to my Union
I have a 2000 F250 that I believe has the same problem. Are you able to repair it? If so, what would you charge for that service?
The instrument clusters in this video only go back to 2002. Your 2000 is not the same and of a different design.
Okay so i got a 1990 ford f350 diesel and the shifter gauge thing that's got park and drive on it the little cable on mine is screwed up and doesn't show what gear im in and i can't find a new one online are you able to find one for my gauge cluster?
So basically re-solder everything? What is the gel looking stuff your putting on the joint before you re-solder? My 2006 f150 keeps going out, coming back on, all the lights will stay on then go back out, odometer blinks off and on. What are the known trouble spots for these cluster's?
This video covers the common problem spots in these clusters. That's flux you see being used on the joints.
@@jeffescortlx Thanks for replying. I had the cluster out before but I did not check the solder points on the resistors. I'll pull it back out and look those over.
@@marka.2715 The solder joints on the resistor network packages are too small to see with the naked eye.
@@jeffescortlx I'll get something to magnify the board with
So if the solder isn't humped over then they need to be redone?
Thank you
Your welcome
Jeff, I repaired one of these for a customer and everything works except now he has the “Door Ajar” light on with doors closed. 02’ Super Duty. Do you know if the is the MCU chip causing this?
Sorry I'm not sure. I haven't run into this one yet.
What are the wires you had to connect to power up the cluster
Great video. Thank you for sharing. What do you typically find wrong when the display is out? I have one to look at today that has a bunch of lights coming on and the chime is constantly beeping as well as no display. I confirmed the problem is in the cluster by installing a known good unit. I'll let you know what I find on it. Thanks again!
I should have mentioned in my earlier comment that I was referring to 05 to 07.
@@align700n fractured joints for the VFD display. Probably in the hot wire circuit somewhere. Could be in the power supply section.
Good job man!
Got a 05 ford f150 brake light stays on can u fix that
Yep I can.
@@jeffescortlx where do I send it
@@robertcousin7623 you can send it to me if you want. My email is listed in the description of this video.
What colours and pins are the power and ground on the connector
Took my cluster out of my 2000 F-150 to upgrade the bulbs to LED and while I had it out I re soldered the ODOMETER joints but when I went to put it back in the truck the gauges were bottomed out and only a couple lights on and the mileage doesn’t work at all now and my truck won’t crank but it will turn over so I unsoldered and still nothing
Can you send me a picture?
@@jeffescortlx What’s your email and I can send you my number so I can text the pics through text and I have 1 video as well
@@jeffescortlx Sent a video and picture via email.
@@alexharper9786 got it.
what wires are you connecting power too when testing?
LOL shipping department, I have a 2006 F250 6.0 and some times my gauges and radio stop working the needlesss on the cluster it looks like the loose power and my radio and all of the sudden they work again.
Yes, that's exactly what this video is for.
Jeff I got a question I can't seem to find a wiring diagram anywhere but do you know if the cluster is tied into the ESOF 4x4 switch inside the cab. I can't find the answer anywhere
I'm not sure off the top of my head. I haven't looked into the wiring diagram for a while. What is the original issue you're trying to solve?
@@jeffescortlx What I'm wondering is if the Cluster short could be the issue why my ESOf switch inside the cab refuses to engage 4x4. I've been chasing the problem down and wanted to see if they were connected. I know the 4x4 icon is in the cluster and it does light up when first started. My next tests will be the control module and T-case shift motor. It's hard to do all this without my Forscan program but it won't be here until Friday now.
I don’t see your email address. I want to see if you repair the cluster on an 03. If so, what is your cost? I will also need to know how to get my cluster to you. Thanks Derek
The year range details and contact email is in the description of this video. You might have to click a down arrow or click on a "more" button for it to show you the video description.
Have you ever done a 2005-2010 ford mustang roush instrument cluster?
No just the regular mustang version.
Having problems with 2006 speedometer not working but everything else in cluster is fine no battery saver symptoms 😢
Try a sweep test:
ruclips.net/video/so7cuTRLibc/видео.html
What tools and materials do you recommend for someone to do this at home ?
T-12 soldering station with j02 tip. Microscope and good flux and solder. Hot air station is nice for doing microprocessors.
Is there a good source for instrument cluster bulbs for the 05-07 Super Duty?
Since they are user serviceable you'll be fine with just about any if you stick with incandescent.
Awsome work. I've got a 2000 F-350 with radio failure intermittently works. No power anything, it's a base model with no extras. I'm not comfortable doing that fine solder work. What do you charge to service a cluster for a 2000 model?
I can be reached for a quote at 1mr.repairman@gmail.com
Are you still repairing these I have a f450 2007 super duty that I am having this issue with
Yes I'm still offering instrument cluster repair service.
What’s he liquid he is putting on the board? Flux?
2 questions for you man! Love your work, I work on the Ford clusters for the Vics, Town Cars and Grand Marquis’ that are prone to the failed odometer display solder joints.
1. What wattage or temp soldering iron are you using on the small resistors, as I seem to have issues melting solder on one pad and the entire resistor transferring heat to the other pad and coming right off. I manage by using some fine-tipped tweezers to hold it, but you breeze through them so much easier!
2. What type of solder do you use?
Keep up the great work and awesome videos man!
I have a feeling the resistors are coming right off the board for you because the other end of the resistor is fractured and there is nothing holding it.
I use a T12 Oled station, I belive 60 watt. Normally set around 350.
@@jeffescortlx That’s very possible, I’m thinking that’s 100% the issue, as the ones I’m fixing do have bad joints. That didn’t even cross my mind 🤦🏼♂️ lol. Thanks for the reply though! I just need to invest in a nice soldering iron and hot air station already.
I believe something in my cluster is causing fuse 41 to blow, which controls radio and windows. Is it a possibility that my battery saver relay is causing fuse 41 to blow often? Any input would be appreciated!
My guess is it's not the cluster at fault. But I'd start by unplugging the radio, power windows and/or dome light to see if the short goes away.
@@jeffescortlxThanks for your reply, The first thing I did was disconnect radio and power window switch and still blew the fuse, that's why I was leaning more towards a bad cluster or faulty battery saver relay
@@flats-hopper4351 the fuse stops blowing when the cluster is unplugged?
@@jeffescortlx for now it hasn't blown for 2 days with cluster unplugged. Only time will tell, but cluster seems to be the issue!
for the love of god can you tell me what wires you have hooked up for the first cluster to power it up on the bench. ive been looking for hours online and cannot find it for the life of me'
I can send you a PDF. My email is in the description and the top comment.
What is that jel? Some sort of flux? Can I use anything, like mint jelly?
Yes it is flux. Mint jelly not recommended.
Great work!
Correct on the std 40watt soldering equipment.
Can you post the equipment you use.
Iron, flux, scope.. etc
What kind of gel flux do you use?
Hey man is this problem common in the 05 ford e250 Cus the same thing is happening on mine. Battery light comes on dash cluster and radio loose power, but its intermittent?
That cluster is a little different, but if I remember correctly it has a similar problem.
Hello sir, are you taking orders for repairs ?
Is there a procedure for 2000 lariat psd?
Questions does the fuel gauge have problems 04 models I've replaced sending unit injectors and the gauge I can drive 13 miles and the fuel level will drop
Yes it's possible for fuel gauge issues to be caused by cluster PCB problems.
@@jeffescortlx ok thanks so I should send it in to circuitboardmedics
@@Bankablefoil you could. Otherwise if you want to support the little guys here is a list of technicians that might have someone local to you. ruclips.net/video/T_2WnJMsZaU/видео.html
What are the symptoms that indicate this type of repair is required?
0:13
@@jeffescortlx Thanks. I did see that. I was looking for some more detail, e.g. with / without truck running. I have a situation where, when the truck is off, and a shut the doors, after 10 seconds or so, the mileage display on the cluster blinks on and off, radio, dome lights turn on and off randomly, and sometimes the doors lock and unlock. It acts possessed, if you will. I'm wondering if this could be explained by the battery saver relay circuit problem you are fixing.
@@mathiassmith8246 it's possible. But I don't believe the cluster has any control over the door locks.
But it's a common enough problem it wouldn't be a bad idea to have the cluster gone through.
Are you using leaded solder or a lead free solder to reflow?
Leaded.
@jeffescortlx thanks! I got a solder station on the way and some tacky flux. Got out the microscope and found a bad solder joint on the blue connector, third pin from far top right. Will also hit the ones in your video. Need to see if the factory prints I have show what this pin goes to.