Instrument cluster lights keep shorting out

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mcgreen418

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Hey group, new member here. I recently purchased my 4th full size bronco. This is a 1989 EB edition. The ignition actuator rod was replaced about 3 weeks ago. I am learning auto repair as I go. I have been in construction my whole life and typically if I can see it I can build it. I never really worked on vehicles in the past other than replacing starters, tune-ups and simple repairs. I did the actuator rod myself and took apart the steering wheel and dash. After completing this task, I drove at night but as soon as I turned on my headlights, the instrument panel lights did not light. They worked before. I replaced the blown 5amp fuse but it continues to blow as soon as the headlights are turned on. I replaced the headlight switch. I also found where I had pinched wires when I put the steering column bracket back on. I taped up those wires and do not see bare wires anywhere else. Any ideas? 

 

miesk5

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Yo mcgreen418,

Welcome!

Saw your post last nightvand spent some time looking for the 89 wiring  diagram to no avail.

Do the gauges operate ok?

Was the headlight switch connector looking ok?  Some get burnt due to switch malfunctions described below @ note 1

I just found a "generic" Haynes wiring diagram shown below for 87-89 and it shows the Light Blue/Red feeds the instrument panel illumination circuit and radio.

I didn't look for more fed by that wire. 

1239.jpg

pic by equivalent

Where it is shorting, I can't  guess.  But at least you can inspect the headlight switch harness to begin.

...

Note 1 Switch Fires, Part Number SW-2103: "...Over the past two years, this office has experienced fires caused by another potential problem in Ford vehicles. The problem exists within the dimmer portion of the headlight switch in Ford vehicles. The light switch involved is a Model SW-2103. These are the pull out type headlight switches usually located in the lower left corner of the front dash of Ford vehicles. The headlight portion of the switch has two pullout positions, the first for parking lights only, and fully out for headlights and parking lights. The shaft of this pull-out light switch can be turned clockwise and counterclockwise which activates a dimmer switch, lowering and raising the intensity of the lighting in the instrument panels respectively. Fully rotating the shaft counterclockwise past a notch activates the interior lights within the vehicles. The potential problem exists within the dimmer portion of this switch. The dimmer mechanism consists of a metallic resistive coil set inside a ceramic disc positioned over the shaft of the switch. The coil is exposed on its front side away from the passenger compartment. The front side of the coil passes across a contact permitting a current to flow through a certain portion of the coil when the switch is pulled our in its first or second positions. The greater amount of coil through which the current is permitted to pass (clockwise most position) creates the greatest resistance and therefore dims the dash lighting to its lowest intensity. The opposite position provides greatest intensity. Through our investigations, we have found that the coil can fail owing to wear and/or possible material defects or damage. A fractured coil can maneuver itself free of the ceramic disc permitting it to come in contact with the metal bracket which mounts and grounds the switch to the vehicle. When this occurs, a current can flow through a portion of the coil creating high temperatures melting the metal material of the coil and possibly igniting surrounding combustibles. This mechanism has been observed in three separate incidents by this office. Two of these resulted in a fire. The mechanism is precipitated by wear and/or defect in the coil mechanism. If the former is true, we expect there will be an increase in fires caused through this mechanism given an increase in service time. To this date the problem appears to be somewhat limited. However, this particular light switch has been utilized in numerous Ford vehicles. Therefore, a small increase in failure rate owing to age and wear could result in a significant increase in fire losses. The SW-2103 Light Switch Assembly discussed above is reportedly installed in the following Ford vehicles: 1986 -1997 F100, F150, F300; 1990-1994 Explorer; 1987-1994 Ranger; 1987-1990 Bronco II; 1992-1997 Aerostar..." Miesk5 NOTE: No Bronco Listed, but this may be the result of typos or incomplete research by the company.

 

cowboyup351

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Hopefully this can help you.  Diagram of the '89 Bronco Instrument Cluster Lighting.

89-bronco-instrument-illumination.jpg

 

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