Cluster swap issue

PirateB · Aug 4, 2013

Swapped an 03 silver face cluster into my 96 2.3 with non-tach cluster. I have all the lights working and gauges except I'm having an issue with the temp gauge.

I'm using the 03 gauge guts with the 96 resistor on the back but when its cold it doesn't even read on the gauge pics attached. Any ideas ?

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PirateB · Aug 5, 2013

Nothing I've tried has worked. Would the temp gauge guts be different from tach to non tach clusters? Seems like the gauge works, just that the sweep is off, regardless of configuration (96 or 03 gauge guts, resistor or no resistor)...

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snoranger · Aug 5, 2013

Around 97 or 98 they changed to a different coolant temp sender. I solved the problem by swapping in an '01 SOHC engine complete with the newer sender... :icon_rofl:

PirateB · Aug 5, 2013

The newer sender has two wires. Possible to adapt this to my 96?

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PirateB · Aug 6, 2013

Heres a quick video of the issue...still havn't figured it out.

http://youtu.be/dl2yHwVk4xE

PirateB · Aug 6, 2013

Well in a last ditch effort I removed the cluster AGAIN and swapped the 92ohm resistor on the temp gauge around thinking maybe it had to go a certain way. Well after that the gauge behaves normally now!!!

I should have placed the needle slightly higher while the truck was warm because it does still fall slightly below the gauge mark on start up but I'm done fooling with it...close enough.

PirateB · Aug 7, 2013

Anybody have any other ideas on this?

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PirateB · Aug 7, 2013

OK...I think the gauge sweep is the issue....if you look at the tachless cluster the temp gauge faces the passenger side, on the cluster with tach it points to the drivers side....so the gauges are not compatible. If you look at the internals side by side they are wound in different orientations. If my original cluster had a tach there wouldnt be an issue.

This weekend Im going to compare 96 and 03 temp senders and if the threads are the same I'm going to grab an 03 sending unit and use that in conjunction with the 03 gauge NOT using the 96 resistor. This should solve the issue. The 03 sender uses 2 wires, one is ground because the 03 uses a composite manifold so its not grounded like the 96 sender. Splicing into my harness and leaving the ground disconnected ought to do the trick. I will update once I try this.

If anyone sees a flaw in my plan please speak up!

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snoranger · Aug 7, 2013

Using all the 03 parts should work fine. You'll just have to ground one of the 2 terminals, Like you already said... Composite intake. I don't think the newer sensor will ground through its body... IIRC from my testing, the circuit was isolated.

PirateB · Aug 8, 2013

Thank you, I can't wait to get this straightened out.

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PirateB · Aug 15, 2013

I just wanted to report the gauge is working perfectly now.

Reinstalled the 03 temp gauge guts (no resistor) then installed an 03 2 wire temp sender and soldered/shrink wrapped in the connector to my harness grounding it to a nearby stud. The hardest part was soldering the wires up under the intake manifold. I did have to shave off one of the alignment tabs on the sender to allow the pigtail I got from rock auto to clip in.

Good news is the gauge works properly and I can now pull the cluster in under 6 minutes LOL

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Cluster swap issue

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