2002 Exp Cluster Issues

[Intricase]

Hello,

Sorry for the book I am about to write....

Specs: 2002 Explorer V6 4x4 XLT 152k mile, certified transmission w/ Dealer installation @ 48k miles. 2nd owner, no reported accidents.

General Problem: Instrument cluster has gone out, back lights still work, dimmer switch works, delay switch is not working, power windows have no power, vanity lights have no power, puddle lights out.

Recent work (6 months ago) - removal of the door jam sensor in the driver and passenger front from the bracket mount and replaced with after market sensor.

Recent problems/work done - (this month) - Cluster went out completely along with the 1st paragraph of problems. 1st fuse #17 blew out, replaced, blew out again, replaced and now it is fine. All other fuses related have been check and are good. Car runs / starts fine. I removed the positive cable and left off for 20 min and reconnected (no dice). I read that if you crossed the positive and negative battery cables off the battery that it "may" reset the GSM (I am not convinced the GSM is bad...yet).

I am going to check the wires in the door jams to search for broken wires and will replace if I come across any, Vanity mirrors are intact and have not been checked for broken / loose wires.

I am posting here on this topic to place pictures and have a log of my adventure into fixing this problem as well as to ask for assistance in locating the problem.

I went through 34 pages into this forum and found one post with similar problems, however I believe mine is a unique.

Thanks...(TBC) :roll:

 

[Intricase]

Ok, I can't figure this out. I have a shot gun and buckshot in hand. What should I shoot first? the fuse box? the engine? the door jam switches? ....Ive never wanted to destroy something of value more in my life than this.

 

[Intricase]

can the circuit breaker #60 fail? I can't tell because it is all silver and you can't see anything inside it. All the auto places I went to do not sell this Circuit breaker. It says in my manual that it is directly connected to the delay switch. With my cluster and all my lights / radio / power windows not working, I am leaning towards this. Anyone out there want to take a crack at this? I'm willing to learn how to do anything at this point.

-Thanks.

 

[Intricase]

day 2, no response. Thanks again explorer forum but you were no help. On to better sites!

 

[BigRondo]

Welcome aboard!!

You have to relax before you go flying off the handle. This is a very friendly forum with hundreds of members who offer very valuable advice. The thing is that people aren't sitting at their computers waiting for questions to answer. We all have lives outside of Explorer Forum.

You have to give it some time. There are people out there that want to help.

Have you tried searching for your issue? I know this issues has been discussed many times.

Only 1 day & 3 hours have elapsed since your first post and your last post, not 2 days. As far as finding a better site, It's not gonna happen.

Having said that, I will check my shop manuals and report back.

 

[Intricase]

Sorry, did not mean to sound so toxic. It has been a stressful week and the car trouble seems to have put mean on the very extremes of my emotions. I meant by my comment that it was "Day 2" not "2 days". I understand people want to help and I have combed over 50 pages of threads trying to find more and more information on this issue.

All that being said.

My next step is to use my voltage meter (after I read the instructions on how to use it) to test how far the power is going from the box-O-fuses associated with the delay lamps / dashboard clusters and try and get as far as I can with that.

This weekend (starting friday night) I will have time to devote to tearing things down and REALLY getting into the problem.

Thanks again,

 

[Intricase]

So I took out the computer after testing the power all the way to it. The computer is recieveing a full 12v but when testing the output to tall the power windows, clusters etc.. nothing hits. Hopefully this is the problem. My computer/controller has a Motorola brand on it. Is this normal?

Thanks,

 

[BigRondo]

Sorry, I forgot about this. I will forward some info from my shop manuals today.

 

[Intricase]

So the computer was not the right one ( I don't think ), I think I pulled the one that has something to do with the transmission, however it runs/drives fine. I can't find the GEM under the dash, this is a late model 2002 XLT. I checked all the boots on the doors and no cracked / broken wires. I'm set that the GEM is bad or has a bad connection. Can anyone help?

-Thanks.

 

[rrgone]

Your title kind of says it all to me. Why aren't you chasing the IC as the culprit? You don't even have a GEM in a late build 2002. Take out the cluster and see if there are visible scorched areas on the back. You might get lucky and see something you are able to fix it yourself or if someone you know can solder. There are lots of places now that repair IC boards. Try google and make some calls or emails, see if any of them can confirm the IC is bad from your symptoms.

The Motorola box you took out is probably the 4X4 Control Module. That is directly behind the glove box.

Please do keep us posted. Good luck.

 

[Intricase]

Sweet! Thanks for the post, I'll stop looking for the stupid GEM box now. I wanted to rule out everything before i pulled the cluster. Does the cluster also control power to the Power Windows / radio? Because that is out as well all at the same time.

I am leaning towards the fact that it is a seperate issue but I wanted the radio / power locks to work before I repaired / bought a new cluster.

 

[rrgone]

It's been too long since I have looked at the wiring diagrams and FSM for the 2002s. I don't even know where they are anymore after a move. From memory, which is getting old, I believe that the GEM functions were largely moved to the IC. So I would start there if it were me/mine.

 

[BigRondo]

I have to ask because I see no mention of you checking the wires in the boot. Did you check for broken/damaged wire(s) in the boot? If so, what were the results?

 

[BigRondo]

Check your PM.

I have just sent the troubleshooting steps for the Radio from my shop manuals.

I have just sent the troubleshooting steps for the Windows from my shop manuals.

I need to know if you have an early or late build so I can send the correct troubleshooting for the gauges.

 

[Intricase]

Awesome! Thanks for all the information!

How would I tell if it was a late model or not?

 

[BigRondo]

Awesome! Thanks for all the information! How would I tell if it was a late model or not?

Check the label on the driver's door jamb. The build date will be there.

Early Build: To March 2002
Late Build: From March 2002

 

[MarkToledo]

Holy cow! We have the same problem! At least it seems like it. I lost all my gauges except for the air bag light for some reason. No speedometer, gas gauge, tach, etc. Plus my radio doesn't come on but the time shows up on the radio when I turn my headlights on.

The overhead lights worked for one day and then went out for some reason.

Anyway, the Dealer I took it too said it is the Instrument Cluster. He said it is like a power gateway to a number of things including the power windows, which don't work either.

I bought a manual and I'm going to attempt to pull off what is necessary to get a look at the IC. I don't know how to test the IC itself to see if it is good or bad. Add to this some of the research I've seen on the IC says that it has to be programmed. I hope that isn't the case because that sounds expensive too.

My car has 77K miles on it. Once I install a new IC, if that is successful, I'm guessing there will be no lasting proof of my mileage.

I just wanted to say that I share your frustration. If I find anything on my path to repair, I will certainly share it with you. Please do the same. Good luck.

 

[Intricase]

So I did check all boots for broken wires and spent a solid 2 hours all together taking off the boot, opening up the guard and carefully using a flat head screw driver i would move from wire to wire and inspect each one going into the door and back into the body. Nothing was broken.

Tonight I will begin to take apart the Instrument Cluster. We can compare notes. I am going to take pictures and update my progress through it 1 screw at a time.

 

[MarkToledo]

Please share the pictures if you would. I watched a couple of teardowns to get to the IC on youtube and they didn't have a good angle or something because you really couldn't see what they were doing. I'm interested in how to get to the bolts on the bottom of the cluster. My manual should be here today so maybe that will be clear when I take a look.

Good Luck!

 

[BigRondo]

There is a write-up for removing the cluster. I will post the link tonight after work.