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Who else has fixed their own instrument cluster???

Fidget_76

SM 2021
Full Member
Joined
Oct 14, 2021
Messages
11
So, today I took on the daunting task of repairing my instrument cluster in my '04 Av. When I bought the truck recently, none of the gauges worked, multiple lights were burnt out and the PRNDL display would fade in and out. I have been very keen on doing as much work on the truck myself as I can.

I have had very little experience with soldering, so before I made the attempt, I did get a simple electronics kit (fm radio) and did that so I at least had some inkling behind what was going on.

Got a cluster repair kit off of Amazon that had the 6 stepper motors and a selection of various coloured LED bulbs. It was around $60 CDN, but did come with a soldering iron, solder sucker, solder and a needle removal tool as well. I also purchased a proper soldering station where I could adjust the temp of the iron. All in all, I probably spent a little bit more than what it would cost to have someone repair it that actually knew what they were doing. My thought/mantra was, "I can't screw it up any more than it already is!"

Took the cluster out, removed all the covers and needles and got to work. I only ripped off 3 of the 24 soldering pads for the stepper motors, which I took as a win, because in a lot of the YouTube videos that I watched, this is a common problem and usually a lot more go missing. Then I re-flooded the chips that handle the PRNDL display, added new blue LEDs, and soldered in the new stepper motors using jumper wires where I tore out the pads.

To my great surprise, the damn thing actually worked! Needed a couple of tweaks to the needles to get them set appropriately, but I don't need to use the speedometer app on my phone any longer, and I can see how much gas I have left!!!

Glad that I took this project on myself. Although I have done a lot of woodworking in my life, electronics were never something that I had really done much with. Now I have a lot more confidence that I can make this stuff work!

Thanks for taking the time to read this, I would love to hear from anyone who has taken on the same project and know how it went for them. ALso, if there is anyone who is thinking of doing it, my biggest bit of advice would be to watch the videos online and TAKE YOUR TIME.
 
Great work fidget! I repaired a couple old Ford Expedition clusters but only had to reflow solder on several spots.
 
Are you trying to make us feel guilty for not fixing our own clusters. LOL 😂

Well it worked, just ordered a kit.
 
HAHA! My plans have worked!! :ROFLMAO:

Make sure to watch the videos on YouTube, they saved me a ton of frustration that I know I would have had. The channel that I found the best information on was https://www.youtube.com/user/jeffescortlx

I found that I didn't lose any of the solder pads until the last two stepper motors, mostly it was because I was getting over-confident at that point. Have some very small gauge wire on hand just in case you need to jumper from the solder point to the terminal on the motor. Reflowing the resistors can be a bit tricky as well as they like to just come off completely, then you have to try to remember which orientation to put them back. Try taking a pic of the ones that you are reflowing and that way you have a visual record of which way they go.

Best of luck man, I look forward to hearing how it goes!!

Are you trying to make us feel guilty for not fixing our own clusters. LOL 😂

Well it worked, just ordered a kit.
 
Thanks for the tips, mine has been out for years. I used alternate methods to read what the cluster used to tell me.
 
Yeah, my gauges goes out one by one it seems. I got the stepper motors from ebay and replace them. First to go was my oil pressure. Damn, I had the oil pan off to change the o-ring, changed the pressure sensor and nearly dropped a bolt into my engine trying to fish out an oil filter near the sensor that wasn’t there (I have an 2004 model) in the first place. Found out it was “only” a dead stepper motor. So from now on I swap out the guage before anything else.
 
That is a very common problem Tausen
Never ever trust a instrument cluster, you have to get some sort of scan tool.
 
Thru the magic of Amazon prime they arrived today. Even came with 4 sets of color bulbs.

IMG_20211026_221407_970.jpg
 
Thru the magic of Amazon prime they arrived today. Even came with 4 sets of color bulbs.

View attachment 233305
That looks like the exact same kit that I got. I picked up a better solder station that allows temp control, but you should be fine with the one in the kit. One tip that I took from the videos that I watched is to add a couple of leds with the leads left long to the odometer so that they can be pointed down towards the ends of the gauge, other wise the middle lights up nicely but it gets dimmer as it moves to the ends. But I guess that is only if you are planning on changing the lights. I went with blue, looks good!
 
I think my fuel stepper motor is going out. Works on/off. Seemed to work more on when I was at 1/2 a tank or below. Was thinking the sender on the aftermarket fuel pump was shotty. After looking around and at the video in this thread it appears to be the motor. Can you get the clear plastic cover as well? There is a crack in mine when an angry elf punched it. 🥵
 
I think my fuel stepper motor is going out. Works on/off. Seemed to work more on when I was at 1/2 a tank or below. Was thinking the sender on the aftermarket fuel pump was shotty. After looking around and at the video in this thread it appears to be the motor. Can you get the clear plastic cover as well? There is a crack in mine when an angry elf punched it. 🥵

When the fuel gauge went wonky on both my Avalanche and EXT, both ended up being the fuel level sender on the fuel pump.

When I replaced each fuel pump with an OEM unit, the issue went away and never returned.

The clear plastic cover is called the instrument cluster lens and replacement parts are available.
 
Update my screens starting working again luckily 😎. Might be the lil black module on circuit board still have two on the way just incase.
I did notice there is correlation with door sensor, if i open driver door the screens will shut off.
Shouldn't turn off unless key is out so possible something else is sending incorrect electronic signals 🤔.
Still upgrading & improving so will see if find culprit
 
I would also double check the fuel pump, my original pump had pressure bleeding back caused some missed starts but second always fired. My replacement seems ok but computer system says some intermittent communication 🙄. Hopefully as I upgrade & replace wiring along with parts fixes improves communication.
Or I might have to pull tank again & spend again better brand?
Replaced all 4 tires & tpms sensors from Amazon I had to convince shop to install as not many willing to add tpms they don't sell. Their programmer was incompatible so search for shop to program new sensors continues or may order myown.
Need to paint new drivers side fender & want to paint match brush guard about same time.
Plenty of work needed on my Avalanche but well worth it.
 
When the fuel gauge went wonky on both my Avalanche and EXT, both ended up being the fuel level sender on the fuel pump.

When I replaced each fuel pump with an OEM unit, the issue went away and never returned.

The clear plastic cover is called the instrument cluster lens and replacement parts are available.
I'm sure you are correct about that. There was once a great thread here on how to rebuild them but it is difficult to find. Thanks for posting the link; that lens cover is close but not 2002 compatible. They used the older style Silverado cluster on the first year Avalanche. 2003-2006 got the updated version and there are tons of options for them. I ended up buying a used cluster just like mine off of Ebay. It will be a quick test by pugging it in and see if anything changes. Then I will use the cover off of it to repair my original. Also have a white face dial kit coming to give it a new look. Just received an Light Blue LED kit for cluster lighting. Will try and use a stepper off the Ebay cluster to add trans temp to mine. The face sticker kit has the that one included.
 
Unfortunately the dang screens decided to quit working again. Blank now past 5 days. Helping hands, soldier kit, & parts here for my attempt when time to remove from truck.
I ordered a new lighting control panel aswell, thought the dimmer control could have contributed to burning chip??
Green leds to add during repair hoping I don't break anything opening indicator hear remove needles can cause them to quit 🙄.
Anyone install resistors to slow led blinking? I ordered parts but unsure where is best to wire in?
The display burning out not long after switch blinkers want to get electronics sorted better, seems like I'm seeing many of the common problems one after another.
 

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