 | Home > Technical > Defender 90 Puma. Bad connection rear of instrument cluster |
 
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| RANGER1312 Member Since: 04 Feb 2018 Location: Fylde Coast Posts: 125   
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Thanks Nick!
What's the best way to test or is it worthwhile just swapping it out providing it's a part then can just be exchanged? |
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29th Apr 2018 12:04am |
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1568  
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Most of the time it’s the stud has gone rusty I wouldn’t wiggle and poke with anything until I’ve done my testing, because once you have you’ll be chasing an intermittent fault forever!
I would have a look on YouTube at voltage drop testing by someone like TST seminars if you’re genuinely interested in learning how to do it properly. You need a wiring diagram and see which portion you have faults intermittently on and narrowing it down possibly to one portion of the header (if three lights aren’t working and they’re all on the same portion, that’ll narrow it down immensely). Inside the header block there’s pins and they connect to a “bus bar” type arrangement ie: four wires might splice together onto it , 6 onto another, 3 onto another - although from the outside eye the plug looks like they all connect together. PaulMC does the pins and plugs for the headers that’s who I get mine off. I couldn’t tell you which part of the circuit is at fault without seeing it and testing it, anyone who says they can let me know where they purchased their crystal ball from 
That header might be an all in one iirc because it earths through the bulkhead stud. Td5 wiring is terrible as is most of Land Rovers wiring from BMW and zee Germans era of ownership. Seeing more and more wiring faults in Td5 Defenders wiring as the age of them creeps up now. Spend a massive amount of workshop time chasing rotten wiring and plugs in my garage now on them with disgruntled customers that just don’t get it Last edited by NickMc on 29th Apr 2018 12:40am. Edited 3 times in total |
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29th Apr 2018 12:15am |
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| RANGER1312 Member Since: 04 Feb 2018 Location: Fylde Coast Posts: 125
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Sounds simple
 
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29th Apr 2018 12:21am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19556
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There are also Earth points on the outriggers and transfer box, the latter is definteky worth checking.
These are in addition to the bulkhead earths. I don't have diagrams to hand but they should be online somewhere or here. Possibly someone has it here. Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧 |
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29th Apr 2018 12:52pm |
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| Andy730 Member Since: 12 Dec 2017 Location: Douglas Posts: 45  
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Apologies not needed, I still have some issues with mine so all discussion is all good. I'm just not sure what else is routed through the instrument cluster (or why?!?!?!) The link to my immobiliser has been removed, and all my passive bits of the security system have been turned off. I am now guessing that there is some other thing linked to the cluster, perhaps the ECU, i say this as i have noticed that sometimes the cluster will partly die (for a few seconds) the rev counter either sticks at what it was showing, OR,it drops to zero, as does the speedo, temp & fuel gauge.. But the ignition light lights up. I think this all points to the earth going into the cluster... But while this happens, the engine splutters a little, and feels under powered... If my problem is actually an earth problem then it is in the plug on the rear of the cluster itself. Andy 2007 Puma Defender 2005 Volvo S60 T5 (for Sundays) 1998 MGF |
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29th Apr 2018 1:23pm |
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| Andy730 Member Since: 12 Dec 2017 Location: Douglas Posts: 45
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So.. i think i now have the problem pinpointed (fingers crossed)
I have removed the instrument cluster and pulled the multi-pin plug apart, in an attempt to to rule out a bad connection within the plug, i have pulled each pin from he plug and soldered each crimped connection in turn. (By that i mean i heated the pin up with my iron and let solder run over the connection.) I am now 100% sure each pin is now trouble free. Sadly, all this has proved is that the problem is NOT the plug, so it MUST be the socket within the cluster itself. 
As it is now, i can touch the top on the plug with my finger and if i gently press the plug and move my finger left & right i can get the fault to appear. So, i think that my next step would be to send the cluster to a repair shop, one that will be able to test and diagnose what could be a dry joint on the PCB of the cluster (not the easiest of faults to find) Anyone got any recommendations for such a place?? Thanks.. Andy 2007 Puma Defender 2005 Volvo S60 T5 (for Sundays) 1998 MGF |
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1st May 2018 8:25pm |
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1568
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Instrument cluster is earthed through the header I’ve described behind the expansion bottle  |
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2nd May 2018 12:04am |
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1568
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If you’re feeling brave it’s probably a cracked solder joint on the cluster connector possibly from what you’ve said? Normally can see them with a good magnifying glass. Or you could try mark he repairs them. |
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2nd May 2018 12:05am |
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| Andy730 Member Since: 12 Dec 2017 Location: Douglas Posts: 45
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I had thought about that. What puts me off is getting to the PCB itself as from what i can tell, disassembly involves removing the needles from each meter. It's the actual removal of these that puts me off. Perhaps i shall have another look, maybe convince myself it is do-able Andy 2007 Puma Defender 2005 Volvo S60 T5 (for Sundays) 1998 MGF |
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2nd May 2018 8:23am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19556
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Havea chat with Gary @ Alive Tuning regarding the repair, he really knows his stuff with IPAC units etc.
Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧 |
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2nd May 2018 12:16pm |
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6479 
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Video by woody32 on the DISCO3 forum. The Defender Puma cluster is the same  1988 90 Td5 NAS soft top
2015 D90 XS SW |
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2nd May 2018 12:59pm |
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| Andy730 Member Since: 12 Dec 2017 Location: Douglas Posts: 45
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That looks like twist and pull rather than a thread... and i guess the fuel/temp are the same from that... I think i will revisit having a look at it myself... Just need a clear afternoon now...
Oh, and thanks for putting the video on, much appreciated!! Andy 2007 Puma Defender 2005 Volvo S60 T5 (for Sundays) 1998 MGF |
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2nd May 2018 4:17pm |
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6479
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I think he covers the fuel and temp ones too. Check the video's comments as I think there's more detail in there as well.
1988 90 Td5 NAS soft top
2015 D90 XS SW |
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2nd May 2018 4:27pm |
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1568
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Martin has beaten me to it, but a Good video on ford cluster Repairs
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2nd May 2018 6:17pm |
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