1996 Bronco/F-Series

Section 13-01: Instrument Cluster, Conventional

1996 F-150, F-250, F-350, Bronco, F-Super Duty Motorhome Chassis Workshop Manual

DIAGNOSIS AND TESTING

Pinpoint Tests

PINPOINT TEST A: FUEL LEVEL READS INACCURATELY

A1 VERIFY POWER AT LOAD SIDE OF FUSE PANEL

Key to RUN.
Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, verify system voltage at the load side of fuse.

Is the voltage greater than 10 volts?

Yes	No
GO to A3.	GO to A2.

A2 VERIFY POWER AT FEED SIDE OF FUSE PANEL

Key to RUN.
Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, verify system voltage at the feed side of the fuse.

Is the voltage greater than 10 volts?

Yes	No
REPLACE the fuse.	REPAIR the wiring to the fuse panel.

A3 VERIFY POWER AT INSTRUMENT CLUSTER

Have cluster connector(s) remain intact.
Partially remove the instrument cluster from the instrument panel.
Key to RUN.
Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, measure the voltage on the ignition wire at the instrument cluster connector to ground.

Is the voltage greater than 10 volts?

Yes	No
GO to A4.	REPAIR the ignition wire.

A4 VERIFY GROUND CIRCUITRY AT CLUSTER

CAUTION: Before checking the continuity of any circuit, make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function, to avoid damage to equipment. Refer to the test equipment user's manual for additional information.

Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, check the continuity of the ground wire at the instrument cluster connector to ground.

Is the resistance less than 1 ohm?

Yes	No
GO to A5.	REPAIR the wire to ground.

A5 CHECK FUEL GAUGE (EMPTY)

Key off.
Disconnect the fuel gauge sending unit.
Connect one lead of the Rotunda Instrument Gauge System Tester 014-R1063 or equivalent to the fuel level sensor input wire at the fuel tank sending unit connector and the other lead to ground.
Set the tester to 22 ohms.
Key to RUN.
Read the fuel gauge.

Does the fuel gauge read E (empty)?

Yes	No
GO to A9.	GO to A6.

A6 RECHECK FUEL GAUGE (EMPTY)

Key off.
Key to RUN.
Tap on the instrument panel.
Read the fuel gauge.

Does the fuel gauge read E (empty)?

Yes	No
F-Series, Bronco, F-Super Duty: REPLACE instrument cluster . F-Super Duty Motorhome: GO to A7.	GO to A9.

A7 CHECK PRINTED CIRCUIT BOARD

Key off.
Disconnect the instrument cluster.
Measure the resistance of the circuit between the SIG terminal of the fuel gauge and connector Pins C1-05 and C2-06.

Is the resistance less than 1 ohm?

Yes	No
GO to A8.	REPLACE instrument cluster.

A8 CHECK FUEL GAUGE SENDING UNIT WIRE

Key off.
Disconnect the instrument cluster and the fuel tank sending unit.
Measure the resistance of the Y/W wire (F-Series front) or Y/LB wire (F-Series and Bronco rear) between the instrument cluster and the fuel level sensor.

Is the resistance less than 5 ohms?

Yes	No
GO to A9.	SERVICE the DB/Y wire (F-Series front) or Y/LB (F-Series and Bronco rear) wire between the instrument cluster and the fuel level sensor.

A9 CHECK CHASSIS GROUND

Key off.
Leave instrument cluster and fuel level sensor disconnected.
Measure the resistance of wire to chassis ground.

Is the resistance less than 5 ohms?

Yes	No
SERVICE short to chassis ground.	GO to A10.

A10 CHECK FUEL TANK SENDING UNIT GROUND

Key off.
Measure the resistance of the BK wire at the fuel level sensor connector to ground at battery.

Is the resistance less than 1 ohm?

Yes	No
GO to A11.	SERVICE the BK wire from the fuel level sensor to ground.

A11 FUEL TANK INSPECTION

Inspect fuel tank for distortion or damage.

Is the fuel tank damaged?

Yes	No
REPLACE fuel tank. REFER to Section 10-01A.	GO to A12.

A12 TEST BOX CHECK — EMPTY STOP

Connect one lead of Rotunda 88 Digital Multimeter 105-00053 or equivalent to the fuel sender signal lead and the other lead to fuel level sensor ground.
When the float rod is against the empty stop (closest to fuel filter).

Does the multimeter read 14-18 ohms?

Yes	No
GO to A13.	REPLACE fuel level sensor. REFER to Section 10-01A.

A13 TEST BOX CHECK — FULL STOP

Connect one lead of Rotunda 88 Digital Multimeter 105-00053 or equivalent to the fuel sender signal lead and the other lead to fuel level sensor ground.
When the float rod is against the full stop.

Does the multimeter read 154-162 ohms?

Yes	No
GO to A14.	REPLACE fuel level sensor. REFER to Section 10-01A.

A14 TEST BOX CHECK — FLOAT ROD TRAVEL

Connect one lead of a Rotunda 88 Digital Multimeter 105-00053 or equivalent, to the fuel sending signal lead and the other lead to fuel level sensor ground.
Move float rod slowly from FULL to EMPTY stop position.

Does multimeter reading decrease slowly?

Yes	No
GO to A15.	REPLACE fuel level sensor. REFER to Section 10-01A.

A15 HARNESS CONNECTOR CHECK — EMPTY STOP

Reattach all fuel indication connectors.
Move float rod to empty stop position.
Key to RUN.
Read fuel gauge.

Does gauge read E (empty)?

Yes	No
GO to A16.	GO to A7.

A16 HARNESS CONNECTOR CHECK — FULL STOP

Reattach all fuel indication connectors.
Move float rod to full stop position.
Key to RUN.
Read fuel gauge.

Does gauge read F (full)?

Yes	No
GO to A17.	GO to A7.

A17 INSPECT FUEL SENDER

Inspect float and float rod.

Is float rod distorted, hitting filter, filled with fuel or loose on float rod?

Yes	No
REPLACE fuel level sensor. REFER to Section 10-01A.	System OK.

PINPOINT TEST B: NO FUEL LEVEL INDICATION, VEHICLES WITH DUAL TANKS (6 PORT FUEL SELECTOR VALVE 7.3L DIESEL)

B1 BYPASS TANK SELECTOR VALVE

Disconnect electrical connector from fuel tank selector valve.
Key to RUN.
Jumper connector terminals No. 4 and No. 5 for rear fuel tank.
Fuel gauge should indicate fuel level in rear fuel tank.
Move selector switch to front tank.
Jumper connector terminals No. 3 and No. 4 for front fuel tank.
Fuel gauge should indicate fuel level in front fuel tank.

Does fuel gauge indicate fuel level in front and rear fuel tanks?

Yes	No
REPLACE fuel tank selector valve. REFER to Section 10-01B.	CHECK for faulty fuel gauge, fuel level sensor and/or wiring. REPAIR or REPLACE as necessary.

PINPOINT TEST C: ENGINE COOLANT TEMPERATURE GAUGE INACCURATE/DOES NOT MOVE

C1 VERIFY POWER AT LOAD SIDE OF FUSE PANEL

Key to run. Measure IP fuse No. 18 (15A) output, using Rotunda New Generation Star (NGS) Tester 007-00500 or equivalent.

Does voltage read between 10 and 15 volts?

Yes	No
GO to C2.	REPLACE IP fuse No. 18 and RETEST.

C2 VERIFY POWER AT INSTRUMENT PANEL

Key to run.
Measure voltage at engine coolant temperature sender input Circuit 640 (R/Y), using Rotunda NGS Tester 007-00500 or equivalent.

Does voltage read between 10 and 15 volts?

Yes	No
GO to C3.	REPAIR Circuit 640 (R/Y) connection and RETEST.

C3 MEASURE ENGINE COOLANT TEMPERATURE SENDER CIRCUIT 640 CONTINUITY

Key off.
Check continuity of Circuit 640 (R/Y) and a known good ground, using Rotunda NGS Tester 007-00500 or equivalent.

Does circuit have continuity?

Yes	No
GO to C4.	SERVICE as required and RETEST.

C4 CHECK GAUGE COLD CALIBRATION

Key off.
Disconnect the wiring connector at the engine coolant temperature sender.
Connect Rotunda Instrument Gauge System Tester 014-R1063 or equivalent to engine coolant temperature sender wiring connector.
Set the tester at 74 ohms and turn key to RUN. Wait 60 seconds.

Does gauge read within COLD graduation?

Yes	No
GO to C5.	GO to C7.

C5 CHECK GAUGE HOT CALIBRATION

Key off.
Disconnect the wiring connector at the engine coolant temperature sender.
Connect Rotunda Instrument Gauge System Tester 014-R1063 or equivalent to engine coolant temperature sender wiring connector.
Set the tester at 9.7 ohms and turn key to RUN. Wait 60 seconds.

Does gauge read within HOT graduation?

Yes	No
GO to C6.	REPLACE engine coolant temperature sender.

C6 CHECK GROUND CONNECTION

Key off.
Check resistance of engine coolant temperature sender hex Circuit 39 (R/W) and engine ground, using Rotunda NGS Tester 007-00500 or equivalent.

Does circuit resistance read less than 0.1 ohm?

Yes	No
REPLACE engine coolant temperature sender.	CORRECT engine coolant temperature sender ground connection and RETEST.

C7 CHECK FLEX CIRCUIT CONTINUITY

Key off.
Remove instrument cluster and check continuity between the cluster flex circuit and the ECT gauge, using Rotunda NGS Tester 007-00500 or equivalent.

Does circuit resistance read less than 0.2 ohm?

Yes	No
GO to C8.	CORRECT cluster flex circuit as required. RETEST.

C8 CHECK FOR CORROSION/POOR CONNECTIONS

Visually inspect the wiring harness connections for corrosion and poor connections.

Is there corrosion? Are there poor connections?

Yes	No
REPAIR as required.	REPLACE engine coolant temperature gauge and RETEST.

PINPOINT TEST D: OIL PRESSURE INDICATOR INACCURATE/DOES NOT MOVE

D1 VERIFY POWER AT LOAD SIDE OF FUSE PANEL

Key to run.
Measure IP fuse No. 18 (15A) output, using Rotunda NGS Tester 007-00500 or equivalent.

Does voltage read between 10 and 15 volts?

Yes	No
GO to D2.	REPLACE IP fuse No. 18 and RETEST.

D2 CHECK GAUGE FOR MID-SCALE GRADUATION

Key off.
Connect the wiring connector to engine block ground.

Does gauge read within mid-scale graduation or slightly above?

Yes	No
GO to D3.	REPLACE oil pressure sender.

D3 CHECK GROUND CONNECTION

Key off.
Check resistance of oil pressure switch hex Circuit 31 (W/R) and engine ground, using Rotunda NGS Tester 007-00500 or equivalent.

Does circuit resistance read less than 0.1 ohm?

Yes	No
REPAIR Circuit 31 (W/R) as required.	GO to D4.

D4 CHECK FLEX CIRCUIT CONTINUITY

Key off.
Remove instrument cluster and check continuity between the cluster flex circuit and the oil pressure gauge, using Rotunda NGS Tester 007-00500 or equivalent.

Does circuit resistance read less than 0.1 ohm?

Yes	No
GO to D5.	CORRECT cluster flex circuit as required and RETEST.

D5 CHECK FOR CORROSION/POOR CONNECTIONS

Visually inspect the wiring harness connections for corrosion and poor connections.

Is there corrosion? Are there poor connections?

Yes	No
REPAIR as required.	REPLACE oil pressure gauge and RETEST.

PINPOINT TEST E: CHARGE INDICATION READS INACCURATELY

E1 VERIFY VOLTAGE GAUGE OPERATION

Key to RUN, engine off.
Headlamps on.
Heater blower/fan on HIGH.

Does gauge pointer move toward the lower portion of the NORMAL BAND (white marked area)?

Yes	No
GO to E2.	CHECK fuse and the battery-to-circuit breaker and circuit breaker-to-cluster wire connections. GO to E6.

E2 VERIFY POWER AT LOAD SIDE OF FUSE PANEL

Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, verify system voltage at load side of warning indicator fuse.

Is system voltage present at load side of fuse?

Yes	No
GO to E4.	GO to E3.

E3 VERIFY POWER AT FEED SIDE OF FUSE PANEL

Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, verify system voltage at feed side of warning indicator fuse.

Is system voltage present at feed side of fuse?

Yes	No
REPLACE fuse.	SERVICE wiring to fuse panel.

E4 VERIFY POWER AT INSTRUMENT CLUSTER

Partially remove instrument cluster from instrument panel. Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, verify system voltage at cluster connector or gauge terminal.

Is voltage present at instrument cluster connector and gauge terminal?

Yes	No
GO to E5.	SERVICE as required.

E5 VERIFY GROUND CIRCUITRY AT INSTRUMENT CLUSTER

CAUTION: Before checking the continuity of any circuit, make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment.

Refer to the test equipment user's manual for additional information.
Using Rotunda 88 Digital Multimeter 105-00053 or equivalent, check continuity of instrument cluster and gauge ground circuitry.

Is ground circuitry good?

Yes	No
GO to E6.	SERVICE as required.

E6 CHECK INSTRUMENT CLUSTER PRINTED CIRCUIT CONTINUITY

CAUTION: Before checking the continuity of any circuit, make sure that there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment. Refer to the test equipment user's manual for additional information.

Check for instrument cluster printed circuit continuity and confirm flex circuit-to-clip and clip-to-gauge contact by physically flexing the wiring and observing continuity. Continuity reading should not fluctuate.

Are wiring and instrument cluster printed circuit OK?

Yes	No
REPLACE instrument cluster.	SERVICE wiring or REPLACE the instrument cluster.

PINPOINT TEST F: SPEEDOMETER/ODOMETER READS INACCURATELY

F1 CHECK SPEEDOMETER/ODOMETER CALIBRATION

Refer to Speedometer Calibration Tolerance Specifications table under Specifications in this section. Be sure to check the odometer calibration. If both the odometer and speedometer are incorrect in the same direction, it is usually a sign that the conversion constant, tire size, or speed sensor ring are different than programmed. A speedometer inaccurate with an accurate odometer is usually a problem with the speedometer module itself.

Are speedometer and odometer calibration within specified limits?

Yes	No
Speedometer normal.	GO to F2.

F2 CHECK FOR "NOT PROGRAMMED" MESSAGE

Does ERROR 3 message alternate with normal odometer display?

Yes	No
GO to F5. RESET conversion constant.	GO to F3.

F3 CHECK TIRE/AXLE CAPACITY

Are tires the same size on opposite ends of a common axle and properly inflated?

Yes	No
DETERMINE conversion constant. GO to F4.	CORRECT condition or ADVISE customer. GO to F1.

F4 VERIFY CONVERSION CONSTANT AND DISPLAY TYPE

Check tire size and type or vehicle rear axle.

Refer to Conversion Constants Chart under Specifications in this section and note conversion constant.

Check whether the conversion constant in the speedometer is co rrect with the following procedure:

Press and hold the RESET button on the front of the speedometer while turning the key to RUN.
Release the RESET button. The pointer will prove out and some codes will appear on the odometer display. If an E is on the left side of the display, the module is programmed for English display mode and should have English graphics (mph). A lower case "o" signifies an overseas (metric) graphics (kph). Verify the graphics and display modes agree. (The number appearing after the type is the microprocessor revision level and is not used in this test.)
Press and release the RESET button again. The conversion constant and the word CAL will be shown on the odometer display.
Verify the programmed conversion constant is the same as that displayed on the chart. Refer to Conversion Constants Charts under Specifications in this section.
Key off.

Is the programmed conversion constant the same as that displayed on the chart and does the programmed display mode match the speedometer graphics?

Yes	No
REPLACE instrument cluster as described in this section. VERIFY proper operation.	If conversion constant is wrong and programmed display mode OK, RESET conversion constant. REFER to Reset Conversion Constant in F5. If conversion constant is OK and programmed display mode wrong, REPLACE instrument cluster as described in this section. VERIFY proper operation.

F5 RESET CONVERSION CONSTANT

NOTE: The module can only be reprogrammed six (6) times.

Reprogram speed conversion constant using the following procedure:

Locate the dealer mode programming enable single-terminal connector. The connector is located at the bottom of the instrument panel below the center of the glove box. On all vehicles, the dealer mode enable wire is Circuit 567 (LB/Y).
Insert metal clip in service wire panel connector. Clip other end to vehicle ground while the key is in the OFF position.
Key to RUN while holding down the trip odometer RESET button on speedometer. Release RESET button.
Speedometer will prove out (sweep across dial and back). The English/Metric and revision levels will be displayed. The last number of the display is the dealer mode programming lockout count. This count shows the number of allowable conversion constant changes remaining. When the count is zero (0), no additional changes can be made to this instrument cluster. If a conversion constant change is required, a service instrument cluster must be ordered.
Press and release RESET button again and PSOM conversion constant (without the decimal point) followed by the word CAL will be displayed.
Press and release the odometer SELECT button as many times as necessary to change conversion constant to the correct value.

NOTE: Pressing and releasing the RESET button to lock in the new conversion constant reduces the number of times the PSOM can be reprogrammed by one count. The module can only be reprogrammed six times. If you change your mind and want to go back to the old conversion constant, turn the key off before you lock in the new constant.

When the correct new value is displayed in odometer window, press and release the RESET button to lock in the new conversion constant.
Key off. Remove the ground wire. Verify proper speedometer operation.

Actual Speedometer or Odometer Value Indicated	48 km/h (30 mph) Actual Speed	97 km/h (60 mph) Actual Speed	Odometer Measure Over Actual 16.1 km Distance (10 miles)
Allowable Range	45-55 km/h (28-34 mph)	93-108 km/h (58-67 mph)	15.4-16.6 km (9.6-10.3 mph)

Is conversion constant now set to the desired value?

Yes	No
Procedure complete.	GO to F4.

PINPOINT TEST G: SPEEDOMETER INOPERATIVE

G1 CHECK REAR ANTI-LOCK LAMP ILLUMINATION

Key to RUN.

Does anti-lock lamp on instrument panel go out after self-test?

Yes	No
GO to G2.	REFER to Section 06-09A or Section 06-09B.

G2 CHECK ODOMETER DISPLAY

Is odometer display on, and do digits appear normal?

Yes	No
GO to G3.	GO to G6.

G3 CHECK FOR PRESENCE OF ERROR MESSAGE

NOTE: ERROR 3 means conversion constant must be programmed. See Pinpoint Test F.

Does the word ERROR appear on the odometer display?

Yes	No
REPLACE instrument cluster. VERIFY proper operation.	GO to G4.

G4 CHECK ODOMETER OPERATION

Does the odometer display mileage increase with vehicle in motion or rear wheels turning?

Yes	No
GO to G9.	GO to G5.

G5 CHECK SPEEDOMETER OPERATION

Does speedometer indication increase with increasing vehicle speed?

Yes	No
REPLACE instrument cluster. VERIFY proper operation.	GO to G8.

G6 CHECK SPEEDOMETER POWER FUSES

Remove and inspect battery power fuse (No. 8) and ignition power fuse (No. 18). Replace as required.

NOTE: If fuses are blown, replace with a new, intact fuse. If new fuse blows, determine cause and service as necessary.

If fuses are OK, do speedometer and odometer now operate properly?

Yes	No
REPLACE instrument cluster. VERIFY proper operation.	GO to G7.

G7 CHECK SPEEDOMETER CONNECTOR

Verify ground on Pins C1-03 and C2-01 with key in RUN.
Inspect instrument cluster connectors and ensure proper fit. Inspect for loose or corroded terminals. Verify locking tabs are in place.

Is resistance less than 1 ohm?

Yes	No
REPLACE the instrument cluster.	SERVICE wiring harness and fuses as required. VERIFY proper operation.

G8 CHECK SPEED INPUT SIGNAL

NOTE: Only wiring harness end of connector is to be probed. Vehicle speed control may be used as a good indicator. If it works normally, then the speedometer module is at least receiving a speed input signal and the wiring and sensor can be assumed to be good.

Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to Pin 4 (speed in +) and Pin 5 (speed in -).

Does the voltage increase smoothly and continuously from 0 to approximately 3.5 volts as vehicle speed increases from 0 to 48 km/h (0 to 30 mph)?

Yes	No
REPLACE the instrument cluster.	SERVICE wiring. CHECK for open or shorted wiring. If no problems are found, REFER to Section 06-09A or Section 06-09B.

G9 CHECK SPEEDOMETER

Does speedometer indication increase with increasing vehicle speed?

Yes	No
Normal operation. ADVISE customer.	REPLACE the instrument cluster.

PINPOINT TEST H: SPEEDOMETER, IMPROPER OPERATION

H1 CHECK SPEEDOMETER OPERATION

Is speedometer free from hesitation or sticking when accelerating or decelerating smoothly? This may be confirmed by performing the following test:

Press and hold the RESET button on the front of the speedometer while turning the key to RUN.
Release the RESET button.

Does the pointer smoothly prove out, or sweep from 0 to maximum speed then back to 0?

Yes	No
GO to H2.	After verifying good power and ground connections, GO to G6. REPLACE instrument cluster . VERIFY proper operation.

H2 CHECK ODOMETER DISPLAY

The trip odometer must be currently displayed for the RESET button to work.
If unsure about missing or extra segments, perform the odometer display self test as follows:

Press and hold the reset button on the front of the speedometer while turning the key to RUN.
Release the RESET button.
Press and release the select button. The odometer will begin with all zeroes and step through the display test each time the select button is pushed. Refer to PSOM Display Test Sequence below for exact display.

The first digit on the left does not always match the other digits.

Key off to exit this test.

Are all odometer digits formed correctly (no extra or missing segments)? Do the select and reset buttons work normally?

Yes	No
GO to H3. CHECK pointer.	REPLACE instrument cluster . VERIFY proper operation.

H3 CHECK SPEEDOMETER POINTER

Does pointer jump or waver at a constant speed?

Yes	No
GO to H4.	GO to H5.

H4 CHECK RABS SPEED SENSOR RING AND SENSOR

Check for presence of the following conditions.

Damaged, missing or bent teeth
Metal chips on speed sensor
Open or shorted sensor
Improper gap between sensor and speed sensor ring

Refer to Section 06-09A for additional information.

Are any of the above conditions present?

Yes	No
REPAIR or REPLACE as necessary. VERIFY proper operation.	REPLACE the instrument cluster. VERIFY proper operation.

H5 CHECK FOR STUCK POINTER

Is pointer stuck at upper pointer stop?

Yes	No
GO to H6.	Speedometer normal.

H6 SPEEDOMETER POINTER PROVEOUT

Press and hold the RESET button on the front of the speedometer while turning the key to RUN.
Release the RESET button. The pointer would normally prove out, or sweep from the lower to upper pointer stop and back again. In this case, the pointer will "jump back" to where it should be in the sweep and continue to sweep normally when the pointer gets to within 180 degrees of the upper pointer stop (about 56 km/h [35 mph]).
Key off.

Does the pointer return to the normal position?

Yes	No
Speedometer normal.	REPLACE the instrument cluster. VERIFY proper operation.

PINPOINT TEST J: SPEED CONTROL, PCM OR ELECTRONIC TRANSMISSION DISPLAY INOPERATIVE OR ERRATIC

NOTE: Follow this procedure only after being referred here from Section 10-03, Powertrain Control/Emissions Diagnosis Manual, or electronic transmission shop manual diagnostics.

J1 CHECK ANTI-LOCK LAMP ILLUMINATION

Key to RUN.

Does anti-lock lamp on dash go out after self-test?

Yes	No
GO to J2.	REFER to Section 06-09A or Section 06-09B.

J2 CHECK SPEEDOMETER SPEED OUTPUT SIGNAL

To determine if there is a short between the PSOM and the speed control module, the vehicle speed control may be used as a good indicator. If it works normally above 56 km/h (35 mph), this means that the speedometer module is at least receiving a speed input signal and the wiring and sensor can be assumed to be good.

NOTE: Only wiring harness end of connector is to be probed.

Use ohmmeter to check for opens in wiring between Pin 7 (speed out) and the affected module. Verify that the terminals in PSOM wiring connector are completely seated in the connector.

Is the circuit open?

Yes	No
SERVICE wiring between speedometer and affected module as required. VERIFY proper operation.	GO to J3.

J3 CHECK SPEED INPUT SIGNAL

CAUTION: Make sure multimeter is in the voltage function and not in the resistance function to avoid damage to multimeter.

NOTE: Only wiring harness end of connector is to be probed.

Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to Pin 4 (speed +) and Pin 5 (speed -).
If available, a frequency counter may be connected to Pin 4 (speed in +) and Pin 5 (speed in -).

Does the displayed frequency of the signal increase smoothly and continuously from 0 to approximately 667 Hz at approximately 48 km/h (30 mph)? OR does the voltage increase smoothly and continuously from 0 to approximately 3.5 volts as vehicle speed increases from 0 to approximately 48 km/h (30 mph)?

Yes	No
REPLACE instrument cluster.	SERVICE wiring. CHECK for open wiring. If no problems are found, REFER to Section 06-09A or Section 06-09B.

PINPOINT TEST K: TACHOMETER INOPERATIVE, ERRATIC, WRONG INDICATION, DIESEL ENGINE

K1 CHECK FUSE

Check fuse.

Is fuse blown?

Yes	No
REPLACE fuse. If fuse blows again, CHECK for short in circuit.	GO to K2.

K2 CHECK WIRING

Check for loose wiring connections in engine compartment or at instrument cluster.

Are connections loose?

Yes	No
SECURE loose connections.	GO to K3.

K3 CHECK INSTRUMENT CLUSTER PRINTED CIRCUIT

Inspect instrument cluster printed circuit for damage, poor connections or open circuits.

Is instrument cluster printed circuit open or damaged?

Yes	No
REPLACE instrument cluster.	GO to K4.

K4 MAKE RESISTANCE/VOLTAGE CHECKS

Remove instrument cluster and make resistance and voltage checks at 14401 wiring harness connector as follows:

Check Pin No. 3 (of Connector A) resistance to chassis ground — should read 1 ohm or less.
Check Pin No. 9 (of Connector A) resistance to corresponding terminal of diesel sensor mating connector or Powertrain Control Module (PCM) pin — should be 1 ohm or less.
On vehicles equipped with E4OD transmission, check sensor wires to Powertrain Control Module (PCM) module for 1 ohm or less. Perform Powertrain Control Module (PCM) test.

CAUTION: Make sure multimeter is in the voltage function and not in the resistance function to avoid damage to multimeter.

Connect battery. Key to RUN. Check for +12 volts at Pin No. 13 (of Connector A). Key off. Disconnect battery.

Are resistances/voltages within specifications?

Yes	No
Condition is not in tachometer. SERVICE wiring.	RETURN to K1 and RETEST.

PINPOINT TEST L: TACHOMETER INOPERATIVE, ERRATIC, WRONG INDICATION, GASOLINE ENGINE

L1 CHECK FUSE

Check fuse.

Is fuse blown?

Yes	No
REPLACE fuse. If fuse blows again, CHECK for short in circuit.	GO to L2.

L2 CHECK WIRING

Check for loose wiring connections in engine compartment or at instrument cluster.

Are connections loose?

Yes	No
SECURE loose connections.	GO to L3.

L3 CHECK INSTRUMENT CLUSTER PRINTED CIRCUIT

Inspect instrument cluster printed circuit for damage, poor connections, or open circuits.

Is instrument cluster printed circuit open or damaged?

Yes	No
REPLACE instrument cluster.	GO to L4.

L4 MAKE RESISTANCE/VOLTAGE CHECKS

Remove instrument cluster and make resistance and voltage checks (using Rotunda 88 Digital Multimeter 105-00053 or equivalent) at 14401 wiring harness connector as follows:

Check Pin No. 3 (Connector 1) resistance to chassis ground — should read 1 ohm or less.
Check Pin No. 10 (Connector 1) resistance to chassis ground — should read 1 ohm or less, if vehicle has 8-cylinder engine. Open circuit if 6-cylinder engine.
Check Pin No. 9 (Connector 1) resistance to negative terminal of ignition coil should be 1 ohm or less.

CAUTION: Make sure multimeter is in the voltage function and not in the resistance function to avoid damage to multimeter.

Connect battery. Key to RUN. Check for +12 volts at Pin No. 13 (Connector 1). Turn ignition OFF. Disconnect battery.

Are resistances/voltages within specifications?

Yes	No
Condition is not in tachometer. SERVICE wiring.	REPLACE tachometer.

PINPOINT TEST M: ALL WARNING INDICATORS INOPERATIVE

M1 TEST FUSE

Key off.
Remove fuse and test for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does fuse test OK?

Yes	No
REINSTALL fuse. GO to M2.	REPLACE fuse. VERIFY indicators operation.

M2 TEST FUSE PANEL VOLTAGE IN

Key off.
Place Rotunda 88 Digital Multimeter 105-00053 or equivalent in volts position.
Connect meter to fuse panel feed Circuit 16 (R/LG) and perform voltage test.

Does circuit indicate a short or open?

Yes	No
REPAIR or REPLACE circuit as necessary. VERIFY system operation.	GO to M3.

M3 TEST INSTRUMENT CLUSTER FEED CIRCUIT

Key off.
Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to instrument cluster feed circuit at fuse panel output and instrument cluster input.
Key to RUN and test feed circuit for voltage.

Does feed circuit test OK?

Yes	No
REPLACE instrument cluster.	REPAIR or REPLACE feed circuit wiring or connectors as necessary.

PINPOINT TEST N: BRAKE WARNING NEVER/ALWAYS ON

N1 CHECK BRAKE WARNING INDICATOR

Key to RUN.
Observe brake warning indicator for proveout.

Does brake warning indicator function properly?

Yes	No
System OK.	If system light illuminates and stays on, GO to N2. If system light does not illuminate, GO to N6.

N2 CHECK PARK BRAKE

Release park brake.
Check to be sure parking brake switch releases.
Key to RUN.

Does brake warning indicator function correctly?

Yes	No
System OK.	GO to N3.

N3 CHECK BRAKE FLUID LEVEL

Move vehicle to a level surface.
Key off.
Open hood and brake master cylinder reservoir.
Check brake fluid level.

Is brake fluid level low?

Yes	No
REFILL brake master cylinder reservoir with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. CHECK indicator operation.	GO to N4.

N4 TEST PARK BRAKE SWITCH

Key off.
Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to park brake switch.
Key to RUN and release park brake.
Check for voltage through park brake switch.

Is there voltage through park brake switch?

Yes	No
REPLACE park brake switch. CHECK for binding of park brake cable. REPAIR or REPLACE as necessary.	GO to N5.

N5 CHECK FOR WIRE TO WIRE SHORTS

Key off.
Inspect wiring for frayed or exposed wiring.
Check connectors for damage.

Is any wiring or connector damage indicated?

Yes	No
REPAIR or REPLACE damaged component as necessary.	REFER to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual for additional information on system wiring diagrams.

N6 TEST FUSE

Key off.
Remove fuse and test for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does fuse test as having continuity?

Yes	No
REINSTALL fuse. GO to N7.	REPLACE fuse. CHECK system for proper operation.

N7 CHECK INDICATOR LAMP

Key off.
Remove brake warning indicator lamp.
Test brake warning indicator lamp for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does indicator lamp show continuity?

Yes	No
REINSTALL indicator lamp. GO to N8.	REPLACE indicator lamp. CHECK system operation.

N8 TEST FOR FUSE PANEL FEED VOLTAGE

Key off.
Place volt-ohmmeter in the volts position.
Connect meter to fuse panel voltage input side and a known good ground.
Turn key to RUN position.

Does fuse panel show feed or input voltage?

Yes	No
GO to N9.	LOCATE and REPAIR short or open in circuit.

N9 TEST BRAKE WARNING FEED CIRCUITS FOR SHORTS OR OPENS

Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to each feed circuit individually and test for short or open circuits. Refer to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual for wiring schematics.

Are any shorts or opens located?

Yes	No
REPAIR or REPLACE damaged circuit as necessary.	GO to N10.

N10 TEST RETURN CIRCUIT

Key off.
Place Rotunda 88 Digital Multimeter 105-00053 or equivalent in the ohms position.
Test return Circuit 57 (BK) for continuity.

Does return circuit test as having continuity?

Yes	No
GO to N11.	REPAIR or REPLACE as necessary.

N11 TEST INSTRUMENT CLUSTER PRINTED CIRCUIT

Key off.
Test continuity of the instrument cluster printed circuit using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does instrument cluster printed circuit test OK?

Yes	No
REFER to Section 06-00 for additional brake system service and the Electrical and Vacuum Troubleshooting Manual for additional wiring information.	REPLACE instrument cluster.

PINPOINT TEST P: CHARGE SYSTEM WARNING NEVER/ALWAYS ON

P1 TEST INDICATOR LAMP

Key off.
Remove indicator lamp and test for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does indicator lamp test OK?

Yes	No
REINSTALL lamp. GO to P2.	REPLACE lamp. VERIFY proper operation.

P2 TEST FEED CIRCUITS

Perform voltage test on Circuits 16 (R/LG), 904 (LG/R) and 38 (BK/O) using Rotunda 88 Digital Multimeter 105-00053 or equivalent. Refer to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual.

Are shorts or opens indicated?

Yes	No
REPAIR or REPLACE circuits or connectors as necessary.	REFER to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual or Section 14-00 in this manual for additional information on charging system.

PINPOINT TEST Q: HIGH BEAM WARNING NEVER/ALWAYS ON

Q1 TEST INDICATOR LAMP

Remove indicator lamp from instrument cluster.
Test continuity of indicator lamp using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does indicator lamp have continuity?

Yes	No
REINSTALL indicator lamp. GO to Q2.	REPLACE indicator lamp. CHECK indicator for proper operation.

Q2 CHECK FEED CIRCUITS

Connect Rotunda 88 Digital Multimeter 105-00053 or equivalent to feed Circuits 38 (BK/O), 15 (R/Y), 12 (LG/BK) and 932 (GY/W) and test each for shorts or opens.

Are short or open circuits found?

Yes	No
REPAIR or REPLACE circuit(s) wiring as necessary.	GO to Q3.

Q3 CHECK RETURN CIRCUIT

Key off.
Check return Circuit 57 (BK) for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does return circuit test as having continuity?

Yes	No
GO to Q4.	REPAIR or REPLACE return circuit as necessary. TEST system for correct operation.

Q4 TEST INSTRUMENT CLUSTER PRINTED CIRCUIT

Place Rotunda 88 Digital Multimeter 105-00053 in ohms position.
Key off.
Test printed circuit for continuity.

Does printed circuit have continuity?

Yes	No
REFER to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual for testing procedures of multi-function switch.	REPLACE instrument cluster.

PINPOINT TEST R: SAFETY BELT WARNING NEVER/ALWAYS ON

R1 TEST INDICATOR LAMP

Remove indicator lamp from instrument cluster.
Test lamp for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does indicator lamp test as having continuity?

Yes	No
REINSTALL indicator lamp. GO to R2.	REPLACE indicator lamp. CHECK system for proper operation.

R2 TEST FUSE

Remove fuse from panel.
Test fuse for continuity using Rotunda 88 Digital Multimeter 105-00053 or equivalent.

Does fuse test as having continuity?

Yes	No
REINSTALL fuse. GO to R3.	REPLACE fuse. CHECK system for proper operation.

R3 TEST SAFETY BELT SWITCH FOR SHORT

Place Rotunda 88 Digital Multimeter 105-00053 or equivalent, in volts position.
Connect meter to Circuits 85 (BR/LB) and 57 (BK) at switch.
Fasten safety belt buckles.
Key to RUN.
Check for voltage through safety belt switch.

Does meter show voltage through switch?

Yes	No
REPLACE safety belt switch. REFER to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual.	GO to R4.

R4 TEST SAFETY BELT SWITCH FOR OPEN

Place Rotunda 88 Digital Multimeter 105-00053 or equivalent in volts position.
Connect meter to Circuits 85 (BR/LB) and 57 (BK) at switch.
Unfasten seat belt buckles.
Key to RUN.
Check for voltage through safety belt switch.

Does meter show voltage through switch?

Yes	No
GO to R5.	REPLACE safety belt switch. REFER to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual.

R5 CHECK FOR VOLTAGE AT SAFETY BELT WARNING INDICATOR

Place Rotunda 88 Digital Multimeter 105-00053 or equivalent in volts position.
Connect volt-ohmmeter to feed Circuit 450 (DG/LG) and return Circuit 57 (BK) at seat belt warning indicator.
Key to RUN.

Is at least 12 volts present?

Yes	No
REFER to Section 13-09 for additional diagnostic information.	GO to R6.

R6 TEST FEED CIRCUIT

Place volt-ohmmeter in volts position.
Perform voltage test on feed Circuit 640 (R/Y).

Does feed circuit indicate a short or open?

Yes	No
REPAIR or REPLACE feed circuit wire as necessary.	GO to R7.

R7 TEST WARNING CHIME MODULE

Perform voltage test on warning chime module at Circuits 640 (RY) and 57 (BK). Refer to Bronco or F-Series Electrical and Vacuum Troubleshooting Manual.

Does warning chime module test OK?

Yes	No
GO to R8.	REPLACE warning chime module. CHECK system for proper operation.

R8 TEST FEED CIRCUIT TO INDICATOR

Place volt-ohmmeter in volts position.
Perform voltage test on Circuit 450 (DG/LG).

Does circuit indicate a short or open?

Yes	No
REPAIR or REPLACE feed circuit wire as necessary.	GO to R9.

R9 TEST RETURN CIRCUIT

Key off.
Place volt-ohmmeter in ohms position.
Test Circuit 57 (BK) for continuity.

Does meter indicate continuity through return circuit?

Yes	No
REFER to Section 13-09 for additional diagnostic information.	REPAIR or REPLACE return circuit wire as necessary.