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 Changing Instrument Clusters
Document Description

FIRSTLY: A Big thankyou goes out to Christopher Nee, for the pictures of the EBII Sports Cluster
This Document Describes the differences between various models of Instrument Clusters fitted to the EA-ED Series Falcons.
It also has information on upgrading an Instrument Cluster, modifications that need to be made, wiring information, and some points to watch out for when performing these upgrades.

With the EA series of Falcons (and Derivatives), there were three models of Instrument Clusters that were fitted to these vehicles. Theses Clusters Featured Orange Painted Needles, with an Indirect Orange (Natural) Illumination, an LCD Based Odometer for the High Series
The Following Images of Clusters have been taken from various EA/EB/ED Models, and include,
  • The High Series Digital Instrument Cluster as fitted to the EA Fairmont Ghia, and all Fairlane, LTD Models.
  • The Sports Series Instrument Cluster (Mid Series), as fitted to EB/ED Fairmont Ghia, all Fairmont, XR6, XR8, and S-Pac Models
  • The Standard Cluster (Low Series) as fitted to Gli, and Futura Models

  • EA/ED Base Series Cluster

    The EA Base Series Cluster has the following Features
  • Orange Top Lit Illumination, with Painted Orange Cluster Needles
  • 220Km Electronic Speedo, with 20Km Speed Numeral Markings, and 2Km Line Markings
  • Fuel Gauge with Electronic Dampening
  • Temperature Gauge
  • Smartlock Warning Lamp (EBII and ED)
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • Turn Signal and High Beam Indicators
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Auto Transmission Power mode indicator (EAIII Onwards)
  • EA/ED Sports Series Cluster

    The EA/ED Falcon Mid (Sports) Series Cluster, as 

Fitted to S, Tickford, and Fairmont Models

    The EA/ED Falcon Mid (Sports) Series Cluster, as Fitted 

to S, Tickford, and Fairmont Models
    The EA/ED Mid (Sports) Series Cluster is somewhat similar to the EA/ED Base series Cluster, with the exception that it has the following extra Features
  • Oil Pressure Gauge
  • Battery Voltage Gauge
  • Low Windscreen Washer Fluid Warning Lamp - (Certain Models Only)
  • Low Coolant Fluid Warning Lamp
  • Low Fuel Level Warning Lamp
  • High Temperature Warning Lamp
  • Cruise Control Indicator (where fitted)
  • Lights on with Ignition off warning lamp
  • 6000 RPM Tacho, with 1000RPM Numeral Markings, and 200RPM Line Markings In addition to these features, the Mid (sports) Series Cluster has the following Features that are common with the Base Series Cluster.
  • Orange Top Down Illumination, with Painted Orange Cluster Needles
  • 220Km Electronic Speedo, with 20Km Speed Numeral Markings, and 2Km Line Markings
  • Fuel Gauge with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Gauge, with high Temperature warning Lamp
  • Smartlock Warning Lamp (EBII and ED Models)
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • Turn Signal and High Beam Indicators
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • ABS Fault Indicator (where fitted - EBII Onwards)
  • Auto Transmission "Power" mode indicator (EAIII onwards)
  • High Series Cluster

    The High series cluster (Or the Digital Cluster) is a mix of the Low and Sports Series Cluster.
    It includes a Classic style (Needle) Tacho, Temperature, and Fuel Gauge.
    Where it differs to the low and mid series Clusters is that it has a Digital (LCD Based) Speedo, Odometer, and Trip Meter.
    It also has a Car Outline warning system, which shows graphically any Doors open, Boot or Fuel Flap is open.
    Finally, it has a Cruise Control On Warning on the Car Outline LCD Panel, as well as a seat beat warning Lamp.
    Other Features include
  • Low Windscreen Washer Fluid Warning Lamp (On LCD)
  • Orange (Top) Illumination, with Painted Orange Cluster Needles
  • Orange Filtered LCD Panels
  • 199Km Electronic LCD Based Speedo
  • 6000 RPM Tacho, with 1000RPM Numeral Markings, and 200RPM Line Markings
  • Fuel Gauge with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Gauge, with high Temperature warning Lamp
  • Seatbelt Warning Lamp
  • Smartlock Warning Lamp (EBII and Onwards)
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • Turn Signal and High Beam Indicators
  • Lights on with Ignition off warning lamp
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Low Coolant Warning Lamp
  • ABS Fault Indicator Lamp (Where fitted - EBII Onwards)
  • Auto Transmission Power mode indicator (EAIII Onwards)
  • Cruise Control Indicator (On LCD)
  • Check Suspension Warning Lamp
  • Vehicle Outline, with Door Ajar, Boot, and Fuel Flap Status Indicators (On LCD)
  • Upgrading and swapping Instrument Clusters

    With exception to the High Series (LCD) cluster, it is possible to change between different Cluster models rather painlessly.
    All the Clusters use the Same Main Wiring Connector, but the High Series Cluster also have an extra connector for the Door Outline LCD Panel.
    Also, the Main Cluster connector has different Wiring Connections going to it, when compared to the Low and Mid Series Clusters. Therefore when fitting a High Series Cluster to a Low/Mid Series Vehicle, you will need to re-wire this connector.

    Upgrading From a Low Series Cluster to a Mid Series (Sports) Cluster
    As mentioned above, fitting the Mid/Sports Cluster to a GLi/Futura Model Falcon is rather painless.
    Some points though you will need to consider when sourcing/buying a mid series Cluster will include,
  • If you have smartlock fitted, make sure you get a sports cluster from a Smartlock Fitted Vehicle (EBII Onwards). Otherwise the Smartlock Jewel may not be present on the Instrument Cluster.
  • The Cruise control Lamp was only made available on EBII Mid (Sports) clusters, so If fitting / or if Cruise Control is fitted, you will need to get a cluster with the Cruise Control Warning Lamp Fitted.
  • If you have a 4 speed electronic Auto, you will need to make sure that you get a Mid (Sports) Cluster from an EAIII or onwards, as earlier clusters may not have the "Power" Warning Lamp.
    If the above has not scared you off, then you are ready to start wiring some extra features to make the Cluster function correctly.
    The Features you will need to wire up include,
  • The Tacho Input for the Instrument Cluster (So as the Tacho Functions)
  • Low Washer Level Warning Lamp (Which will require a Low Washer Switch, and wiring to function).
  • Replacing the Low Oil Pressure switch, with an Oil Pressure sender. (In order for the Oil Pressure Gauge to function correctly).
    Information for these steps are detailed further on within the document.

    Replacing a Low/Mid Series Cluster with the High Series Cluster Model
    There are a few points that you will need to remember when considering to fit the High Series (LCD) Cluster to a GLi/Futura/S/Fairmont Model Falcon.
  • If you have smartlock fitted, make sure you get a High Series cluster from a Smartlock Fitted Vehicle (EBII Onwards). Otherwise the Smartlock Jewel may not be present on the Instrument Cluster.
  • If you have a 4 speed electronic Auto, you will need to make sure that you get a Mid (Sports) Cluster from an EAIII or onwards, as earlier clusters may not have the "Power" Warning Lamp.
  • The Odometer Reading is stored electronically, via an EEPROM. This will either need to be changed to match the current Vehicle Odo Reading, or a cluster with a similar Odo Reading will need to be sourced.
  • You will need to source the 20 Pin 3rd Electrical Connector, that is used to send the extra information to the Cluster.
    If you have found a cluster, and a connector that matches the above criteria, then you are ready to start re-wiring the cluster connectors to make the new Cluster function correctly.
    Re-Wiring the Cluster electrical connectors will be a long process, and just some of the electrical connections you will need to change will include
  • The Tacho Input for the Instrument Cluster (So as the Tacho Functions - For Low Series Cluster Upgrades)
  • Low Washer Level Warning Lamp (If not fitted previously - Which will require a Low Washer Switch, and wiring to function).
  • The Oil Pressure Sender MAY need to be replaced to an Oil Pressure switch, if swapping from a Sports Series Cluster (The Low Oil Pressure Lamp may glow dimly when using an Oil Pressure Sender, instead of a switch)
  • The Door Switch Wiring will need to be cut for EVERY Door, and a Relay, and resistor array will need to be spliced in, and wired up, for the Door Open LCD Warning to work.
  • The Existing Wiring Connector for the Instrument Cluster will require HEAVY Modification, (I.E. Wires will need to be cut, and resoldered in to new positions), In order for the High Series Cluster to work.
    Information for these steps are detailed further on within the document.

  • Swapping Odometer Readings

    Obviously, when swapping Instrument clusters, you will want to keep the same Odometer Readings for your vehicle.
    For the Low, and Mid Series Clusters, this is not too difficult, but will require the Instrument Cluster to be disassembled in order to do this.
    Because the high series clusters have a digital Odometer, simply cracking open, and winding the Odometer backwards will not work.
    So how is the Odometer reading changed ?
    Firstly, you will need to know a little bit about electronics.
    The Odometer Reading, as well as the Trip meter, Service spanner setting, and possibly other settings, are stored in a device known in the Electronics industry as an EEPROM, or E2PROM, (pronounced E squared Prom).
    An E2PROM is an Electrically Erasable, Electrically Programable, Read Only Memory, very similar to the Flash upgradeable Computer Bios.
    Anyway, without boring you on how an E2PROM works, the model used in the VDO Instrument Clusters is an X24C44 Surface Mount model.
    It is this chip that stores the Odometer, as well as other readings.
    When swapping Instrument Clusters, you will need to Re-Program this chip, if the Odo Reading is well outside of the desired range.
    Unfortunately, I have no idea on how to re-program this chip, and as such, you will need to either take the cluster to an authorised Ford Dealer, or to a Instrument Cluster calibration specialist.
    Adding an Oil Pressure Sensor

    Because the Low and High series Instrument Clusters do not have an Oil Pressure Meter, these vehicles do not have an Oil Pressure sensor fitted.
    Instead of the Oil Pressure sender, they use an Oil Pressure switch.
    What is the difference between these Oil Switch sender thingies I hear you ask ?

    The Oil Pressure switch is just that, it switches to Ground when the Oil Pressure drops below a certain level.
    This means that the Oil Pressure switch is only good for Switching a low Oil Pressure Lamp On or Off.
    If a Mid series Instrument cluster is used with an Oil Pressure switch, the Oil Pressure gauge will either show 0 Oil Pressure, or very very High Oil Pressure, with no intermediate pressure.

    The Oil Pressure Sender has a constantly variable Voltage, that is directly related to the Oil Pressure.
    Obviously, this variable voltage is required for an Oil Pressure gauge.
    Likewise, if fitting a High Series Cluster, to a vehicle that originally had a Mid Series Cluster, then you will need to swap the Oil Pressure sender, with an Oil Pressure switch.
    Without making this change, the High Series Clusters Oil Pressure Warning Lamp will glow Dimly under Normal Operating conditions.
    With the Pressure sender, this is Normal, but obviously not ideal.
    Finally the Mid Series Instrument Clusters also compare this voltage, and if the Voltage falls below a predetermined level, the low Oil Pressure Warning lamp is Illuminated.

    The Oil Pressure Switch, and Oil Pressure sensor are located in exactly the same place, and as stated above, if fitting a Mid or High series Cluster, (I.E. upgrading from a Low series cluster), the Oil Pressure switch will need to be replaced with an Oil Pressure sensor.
    These sensors are located roughly about 2 inches above the Oil Filter, on the Inline 6 motors.
    The sensor also has a single wire coming from it, with a spade electrical connector.
    The Oil Pressure sensor can be purchased from Wreckers for around $20.
    Or alternatively, can be bought from Ford for around $50.00 - Ford Part Number EF-9D290-A
    Wiring the Tacho for Mid and High Series Clusters

    If fitting a Mid or High series Cluster to a Low Series Model, you will need to run 1 wire from the Engine Bay (More specific, the Pink Wire that is coming off the top of the Ignition Coil), to the Instrument Cluster.
    For the Mid (Sports) Series Cluster, this wire needs to be run to the Lower Connector, Pin 8.
    For High Series (LCD) Clusters, this wire needs to be run to the Upper Main Connector, Pin 2.
    PLEASE NOTE : When Purchasing/sourcing an Instrument Cluster, ENSURE that you get the same model that is suitable for your engine type !
    I.E. If you have a 6 cylinder, then you will need to source a 6 Cylinder Instrument Cluster.
    Likewise, If fitting an Instrument Cluster for a V8, then the Instrument Cluster MUST BE OBTAINED FROM A V8 MODEL !
    The Tacho sections for these models are different, and will therefore will be outside of calibration (I.E. V8 Cluster in a 6 will read a lower RPM, and a I6 Cluster fitted to a V8 will read a Higher RPM)
    Adding the Power Line for the Volt Meter (When Fitting a Mid/Sports Cluster)
    When fitting the Mid series Cluster, you will need to add 1 wire from the Battery (+) Positive Terminal, in order for the Battery Volt Meter to function correctly.
    The Wire needs to be connected to the Pin 9, on the Upper Instrument Cluster Main Connector (The 12 Pin Connector).
    If you are lazy, it is possible to simply run a wire from Pin 6 or Pin 7, on the Lower Instrument Cluster Connector (The Ignition Power Input Lines).
    If you are up for the work, you could run this cable to either the ignition switch, or Radio Constant Power Supply. (Doing this will allow for slightly more accurate readings from the gauge)
    Adding the Low Coolant sensor
    This is a worthwhile modification that can be made to the EF and EL Series model Falcons, as it is relatively inexpensive to do, and it can be added to ALL Instrument clusters, (low, Mid, and High Series).
    Considering the number of cases of Head Gasket Problems with the EF and EL, this modification could save you a lot of money !
    The only models that do not have the low Coolant Sensor are unfortunately, the GLi models.
    The Low Coolant Sensor is integrated in to the Plastic coolant Bottle, but can be added to an existing coolant bottle.
    The part you will require is 10K888-AA, the low coolant level sensor.
    This part simply screws in to the existing Coolant Overflow Bottle, but you will need to remove the blanking plug first.
    Once this part has been fitted, you will then need to wire it up to the Instrument cluster
    One wire is Black, and is connected directly to ground.
    The other wire colour, Yellow/Red, should be connected directly to the Instrument Cluster, low coolant lamp, On the Right Hand Side connector, Pin Number 3.
    Finally, you will need to add the Low coolant sensor Bulb to the Instrument Cluster.
    This Bulb is located right next to the LCD Panel, on the Right Hand Side (With the Back of the Instrument Cluster facing towards you). The socket for this bulb may be blanked out by a round paper sticker, simply remove this sticker, and fit a new Bulb and Bulb Holder.
    Adding the Low Windscreen Washer Sensor

    The Low Windscreen Washer Fluid Sensor detects when the level of the Windscreen washer fluid falls to a level that allows only a few more seconds of Windscreen washer operation.
    The Warning lamp is integrated within the LCD Odometer panel, on the EF and EL Series Falcons, and surprisingly enough, it is actually available on all clusters.
    Unfortunately, if you have a GLi Model, without ABS, then you will not have the electrical connector, and wiring already available.
    EF/EL Futura Models, and GLi Models with ABS fitted will have this connector already fitted, and wired up, so all that is needed is to add the Low Washer Fluid Switch, which is part of the Windscreen washer Bottle.
    The Windscreen washer Level sensor is a simple On Off switch, and is integrated within the Washer Bottle, using a rubber grommet. The sensor can be removed and fitted, but you would probably find that it is easier to simply purchase a new/used Bottle with the sensor already fitted, from a Fairmont, Fairlane or LTD.
    The electrical connector is a Female T piece, and is exactly the same type as used on the Front Turn signals.
    This piece has 2 wires coming from it, 1 wire is connected directly to ground (Black), and the other wire goes to the Instrument Cluster Right hand side connector. (Pink/Yellow wire)
    (See below for Wiring Information, in regards to the Right Hand Side Instrument Cluster Connector).
    As mentioned above, when the Windscreen washer level drops to a low level, this switch conducts, causing the Pink/Yellow wire going to the Cluster to be grounded. The Instrument Cluster will then illuminate the Warning segment, on the LCD Panel.
    Wiring Information for the EA Low and Mid Series Instrument Clusters (Main Connector)

    EA Falcon Low and Mid Series Instrument Cluster Connector 1 (Upper Main Connector)
    NOTE : Does not include ABS Warning, Power/Econ, and Smartlock LED wiring

    Pin No Low Description Mid Description Input Wire Colour
    Pin 1 Illumination Input - Illumination Input - Rheostat -VE Blue/Red
    Pin 2 Illumination Input + Illumination Input + Park Lamps + Brown
    Pin 3 Left Hand Indicator Left Hand Indicator +12V Green
    Pin 4 Ground Ground - Battery Black
    Pin 5 Ground Ground - Battery Black
    Pin 6        
    Pin 7        
    Pin 8 Ground Ground - Battery Black
    Pin 9   Volt Gauge Input + Battery Yellow/Black
    Pin 10 Temperature Gauge Input Temperature Gauge Input Variable Voltage Red/White
    Pin 11 Right Hand Turn Signal I/P Right Hand Turn Signal I/P +12V On Green/Brown
    Pin 12 High Beam Input High Beam Input +12V On Green / Orange

    Lower Connector (16 Pin) for Low and Mid Series Instrument Clusters
    NOTE : Does not include ABS Warning, Power/Econ, and Smartlock LED wiring

    Pin No Low Description Mid Description Input Wire Colour
    Pin 1 Ground (Signal) Input Ground (Signal) Input Ground Black
    Pin 2 Fuel Gauge Input Fuel Gauge Input Sender Yellow/Green
    Pin 3 Rear Window Demist Input Rear Window Demist Input +12V On Violet/White
    Pin 4 Low Oil Pressure Input Oil Pressure Sender Input Ground 0 (Lamp On) - High Impedance 7 White/Red
    Pin 5 Alternator Fail Input Alternator Fail Input Ign On/Alt Off Grey/Yellow
    Pin 6 Ignition Switch Input Ignition Switch Input +12V Ignition on Red/Green
    Pin 7 Ignition Switch Input Ignition Switch Input +12V Ignition on Red/Green
    Pin 8   Tachometer Input PWM From Sender Pink/Blue
    Pin 9 Low Coolant Input (Not all models) Low Coolant Input 180R On, 1380 Off Yellow/Red
    Pin 10 Low Washer Input (Not All Models) Low Washer Input Ground On Pink/Yellow
    Pin 11        
    Pin 12 Park Brake Input Park Brake Input Ground On Orange/Green
    Pin 13 Brake Fail Warning Brake Fail Warning Ground On Violet/White
    Pin 14        
    Pin 15 Speedo Supply Output Speedo Supply output +5V Red
    Pin 16 Speedo Signal Input Speedo Signal Input PWM from speedo sender White
    Wiring Information for the EA/ED High Series Instrument Clusters (Main Connector)


    High Series Main Instrument Cluster Upper Connector (12 Pin)
    NOTE : Does not include Smartlock LED wiring

    Pin No Description Signal Wire Colour
    Pin 1 Ignition Input +12V Ign Switch Red/Green
    Pin 2 Tachometer Input PWM from sender Pink/Blue
    Pin 3 Ground Signal Battery - Black/Green
    Pin 4 Speedo Supply Output +5V Red
    Pin 5 Speedo Signal Input PWM from speedo sender White
    Pin 6 Park Brake Input Ground On Orange/Green
    Pin 7 Alternator Fail Ign On, Alt Off Grey / Yellow
    Pin 8 Brake Fail Ground On Violet/White
    Pin 9 Boot Lid Open Ground On Black/Orange
    Pin 10 Check Suspension Warning Ground On Green
    Pin 11 Low Oil Pressure Warning Ground On White/Red
    Pin 12 Battery Power +12V Yellow/Black

    High Series Main Instrument Cluster Lower Connector (16 Pin)
    NOTE : Does not include smartlock LED wiring

    Pin No Description Signal Wire Colour
    Pin 1 Left Front Door Input 180R Closed / 1380R open White/Red
    Pin 2 Left Rear Door Input 180R Closed / 1380R open Black/Red
    Pin 3 Fuel Gauge Input Sender Voltage Yellow/Green
    Pin 4 Fuel Flap Open Input 180R Closed / 1380R open  Blue/Black
    Pin 5 Low Coolant Warning 180R Off / 1380R On Yellow/Red
    Pin 6 Right Front Door Input 180R Closed / 1380R open White
    Pin 7 Right Rear Door Input 180R Closed / 1380R open Black/Orange
    Pin 8 Low Washer Fluid Warning Ground On Pink/Yellow
    Pin 9 Diagnostic Input +12V No Wire Present
    Pin 10 Ground Input Ground Black
    Pin 11 Ground Input Ground No Wire Present
    Pin 12 Buzzer Control O/P +12V On White/Black
    Pin 13 Cruise Control Input +12V On Violet/Blue
    Pin 14 Ground Input Ground No Wire Present
    Pin 15      
    Pin 16      
    Wiring Information for the EA/ED High Series Instrument Clusters (Secondary Connector)


    High Series Secondary Instrument Cluster Connector (20 Pin)

    Pin No Description Signal Wire Colour
    Pin 1 Illumination (-) Input Rheostat -Ve Dim Blue/Red
    Pin 2 Illumination (+) Input Park Lamps +Ve Power Brown
    Pin 3 Right Hand Turn Signal Input +12V On Green/Brown
    Pin 4 Left Hand Turn Signal Input +12V On Green
    Pin 5 Ground I/P Ground Black
    Pin 6 LCD Illumination Input (+) +12V 30
    Pin 7 LCD Illumination Input (-) Display Intensity Switch 88HBlack/White
    Pin 8 Rear Window Demister Input +12V On Violet/White
    Pin 9 Check Suspension Input Ground On Green
    Pin 10 Alternator Fail Warning Ign On, Alt Off Grey/Yellow
    Pin 11 Low Oil Pressure Warning Ground On White/Red
    Pin 12 High Beam Input +12V On Green/Orange
    Pin 13 Temperature Gauge Input Sender Voltage Red/White
    Pin 14 Park Brake Input Ground On Orange/Green
    Pin 15 Brake Fail Input Ground On Violet/White
    Pin 16 Power/Econ Mode (EAIII Auto onwards) Ground On Green
    Pin 17 Check ABS Lamp Ground On White/Blue
    Pin 18 Ignition Input +12V Ignition Switch Red/Green
    Pin 19 Ignition Input +12V Ignition Switch Red/Green
    Pin 20 Ground Ground Black/Green
     
     Document Summary
     
    Document description: Information on Swapping EA to ED Falcon, Fairlane, LTD Instrument Clusters
    Document written by: Matti on 30 2004>, Copyright © 2005 Matti, all rights reserved.
    Document revised: 17 2005 - Revision 3.0
    Document views: 42915 since 30 2004



     

     

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