CUCV Instrument Cluster Repair - Steel Soldiers::Military Vehicles Supersite

Warthog · 11-13-2009, 11:19

Anyone have a suggestion on how to repair the circuit board on a M1009 CUCV instrument cluster.

One of the tabs for the wiring connects has broken off. Red arrow in picture.

I know I can buy a replacement for $80 but like everyone else I am too cheap.

Thanks

Armada · 11-13-2009, 18:18

If you can get the film coating peeled back a bit from the copper path, try a piece of metal tape to make up the difference. Remove the adhesive from the tape in the area contacting the copper path and add a dab of rtv (or something similar), over the top to hold it in contact with the copper. May get you by until you can find someone parting out a cluster.

Warthog · 12-18-2009, 17:04

Ended up repairing the cluster with a piece of copper wire.

I had some small diameter wire and used a hammer to flatten it. After trimming it to size,I used a 25w soldering iron and tinned the two peices together.

To hold the "new" piece in place I used some superglue.

I also had to restore a couple of light sockets. I heated the plastic up with a heat gun and reformed the plasitc. Then I smoothed it with a file.

Sorry for the picture quality. It was late.

M813rc · 12-18-2009, 17:47

Warthog, if you still have the cluster out, could you take a picture of the entire back (or a couple of pics that show the whole thing)? I would appreciate it.
The TM's seem very vague on the layout (or I can't find it!).

Cheers

Warthog · 12-18-2009, 18:23

As a matter of fact I do have it out. I will take pictures.

I also traced down all of the leads and made a diagram of it. I also labeled all of the wires w/colors at the wiring harness and where they go to.

It is at work and I will post it on saturday.

lavarok · 12-18-2009, 21:04

Great idea on how to repair! I'll have to remember that one.

M813rc · 12-19-2009, 01:19

Quote:

Originally Posted by Warthog

As a matter of fact I do have it out. I will take pictures.
and I will post it on saturday.

Excellent, thank you!

Cheers

Edit- and, as promised, he did. Check here-
CUCV-Instrument Cluster Decoded

1986Blazerk5 · 07-06-2010, 01:12

Is there a way to replace bulbs with out removing the whole cluster

reloader64 · 07-06-2010, 08:54

You can replace the bulbs with the cluster in place, from the back. You have to really reach up behind the dash, but it is possible.

Scott

M813rc · 07-06-2010, 16:54

A little known fact is that a popular movie was actually inspired by watching a guy replacing the dash lights in his CUCV....
If you master the technique, you too can change your bulbs without personal injury.

Cheers

(A mind is a terrible thing to waste, I should be ashamed of myself...)