Replacing gauge cluster light bulbs - ugh!!!

[rfuerst911sc]

I apologize for the long rant for what should be a simple replacement. So my 2001 GMC diesel dually exhibited the classic odometer/gear selector failure . I did the pounding on the cluster face to get the intermittent failure to correct itself but that only worked for a while . Online searches said this was a common failure and can be corrected . I have been waiting for warmer weather due to plastic parts involved that have to be removed . Yesterday was warm here so I removed the cluster .

There is a common solder failure point on this vintage GM product. Plenty of videos showing how to perform the repair . Between my wife and I we have 60 years of solder experience so the repair was easy to perform . So far so good

The " while I am in there " syndrome struck and I figured I should replace the 24 year old cluster lights . This is where it all went wrong . So there are 10 bulb holders that are a simple 1/4 turn to remove from the PCB . Six are larger in size the other four are smaller . Online searches found several topics stating the bulbs are " easily pulled out " of the holders and replaced with wedge style bulbs . No frigging way !!!!

I pulled/tugged and used soficient profanity and nothing . Stepped up to using tools with the results being two broken glass bulbs . I went to four different parts stores and they all said they should pull straight out . No one at the parts store were successful pulling out a single bulb .

After a LOT of online research it looks like the bulb/holder are assembled as one piece from the factory. They are wedge style bulb bases but the leads are extended and wrapped around contacts inside the holder . That's why they won't pull out . So I have ordered two different aftermarket bulb holders from an online retailer and these bulb holders ARE designed to take the wedge base bulbs . I hope I ordered the right sizes .

It should have taken 5 minutes to replace 10 bulbs . The new holders are due Saturday so hopefully all will be well this weekend . What a pain in the a$$ !!! The pics below show the back of the cluster and the two different bulb holders/bulbs . End of rant , again I apologize for the used band width .

[fastfredracing]

Timely thread. Guess what I am doing today . It came in for an oil pressure sending unit, but it is not the sender, rather the stepper motor for the cluster .
Im gonna have a go at replacing myself 2004 One ton dump.
My 2004 dually, has the same failure as yours .Its intermittent, but always happens in cold damp weather .

[fastfredracing]

Oh, and if you think these are a pain... My international roll back truck. has 17 bulbs . $22 each . I found replacements online, but several of them burnt out again within weeks of replacement .
I also was pretty sure, I was going to break the circuit board trying to get them in and out . Total brutality , twisting those little plastic fuchers to near the point of failure .
Good luck !

[GH85Carrera]

My El Camino is a SS model, but it came with just idiot lights. The only gauges were the speedometer, and the fuel level.

I found a replacement gauge cluster from a local salvage yard. They destroyed the circuit board somehow when they removed the cluster. I swapped over everything, and had to go the the online forums to get the wiring diagram. I built my own wire harness and it has worked fine for years.

One thing about 80s cars is the dash was poorly lighted. "While I was in the there" I painted the back for the blue plastic gauge holder white to reflect more light, and found some brighter bulbs. The new cluster came with a speedometer that had a trip odometer. I had sent it out to a speedo shop to get rid of all the stupid giant 55 in red, and make it a 115 MPH speedo, not top out at 85, and to set it to the approximate mileage the Elky had.

The dash is much brighter, and it is nice to have a tach, temp, oil pressure gauge in addition to the rebuilt speedo with no reference to the insane 55 MPH limit back then.

It was a real effort, but after many miles and years it all works great. A big improvement.

[rfuerst911sc]

Fastfred if you do a search on GM truck odometer failure you will see plenty of videos on the repair . There is a single row of about 8 pins soldered to the board . The failure seems to always be one or both end pins . In my case both end pins were missing solder . I assume a combination of poor solder wetting and/or cold solder joints .

It is a figidity repair but not hard . Small steady hands help along with a small tipped solder iron . My wife has soldered so much military hardware she can do it in her sleep . In regards to the bulb holders , if I ordered the correct sizes I plan to put dielectric grease on all contact points . Hopefully that makes them easier to install and remove in the future if needed . Good luck with yours .

[john70t]

Originally Posted by GH85Carrera

with no reference to the insane 55 MPH limit back then.

What no GPH display?
2rd gear is not used nearly enough

An old idea, at one point, was to add plate with a 1.25" gauge cluster to the old center console.
-A Fuel/Air monitor for every cylinder pipe. Bung welded in. Ceramic dipped pipes. etc.
-EGT for each bank. At least.
-Cylinder head temp sensors for each bank.
-Visual light warning when a set limit was exceeded.
-Monitor the engine constantly.


New vehicles freak out whenever you back it up with the door open, have heavy groceries on the seat, or dare to drive a block without seat belt.
They are missing the important stuff..

[GH85Carrera]

In my El Camino, I have to wind a crank lever to roll a window up or down. I have to reach over to lock or unlock the passenger door lock. There are no batteries in my keys!

It does have a OBD1 port to tell me if a sensor is out of range with a special reader. Or I can have it blink the Service Engine soon light and count the pulses and decode the error. A few years ago the SEL light came on and dug out the reader and it said than my throttle position sensor was out of range. A new on was cheap, and very easy to replace.

No ABS, traction control, vehicle stability, back up cameras, or tire pressure monitors.

[rfuerst911sc]

^^^ Glen my dually has manual crank windows , manual door locks . The mirrors are manual and the transfer case is lever controlled vs electronic . There is nothing wrong with the KISS principle

[red-beard]

Now you know where "Cluster $%&#" comes from...

[rfuerst911sc]

Originally Posted by red-beard

Now you know where "Cluster $%&#" comes from...

Exactly

[rfuerst911sc]

The bulb holders were delivered today . I ordered the # 5 and # 10 sizes and they fit ! Drove to FLAPS and bought # 74 and # 194 bulbs .

Put a light coat of dielectric grease on bulb bases and holders and assembled . Happy to report they work . And so does the repaired odometer and PRNDL displays . Good for another 200,000 miles 😆