Installing a TC cluster into a 89-95 Ranger dash
The Ranger cluster has two 14 pin connectors that operate the cluster and
warning indicators. The TC cluster only has one 18 pin cluster. Here
is the layout for both clusters
| Moving pins from the Ranger to TC cluster |
| |
| Ranger connector |
|
TC Connector |
| Location |
Wire color circuit # - description |
Location |
Wire color circuit # - description |
| 4B |
R/Y 640 - Power Run/Start |
→ |
1 |
R/Y 640 - Power Run/Start |
| |
|
→ |
2 |
W/PK 160 - OverBoost indicator |
| 8B |
P/W 977 - Brake indicator |
→ |
3 |
P/W 977 - Brake indicator |
| 12A |
Y/W 29 - Fuel sender (anti slosh fed) |
→ |
4 |
Y/W 29 - Fuel sender |
| |
|
→ |
5 |
R/O 655 - Ampmeter |
| |
|
→ |
6 |
Y/LG 654 - Ampmeter |
| |
|
→ |
7 |
Left empty, gauges now powered by SS IVR |
| 1B |
W/R 31 - Oil Pressure (switch) |
→ |
8 |
W/R 31 - Oil pressure |
| 11B |
BK/LB 41 - Coolant temp sensor |
→ |
9 |
R/W 39 - Coolant temp |
| |
|
→ |
10 |
Power from SS IVR - powers 5V gauges |
| 2A |
PG/LG 450 - Seat Belt indicator |
→ |
11 |
DG/LG 450 - Seat belt indicator |
| 2B |
BK 57 - Ground |
→ |
12 |
BK 57 - Ground |
| 5A |
LB/R 19 - Dimmer Illumination |
→ |
13 |
LB/R 19 - Dimmer Illumination |
| 8A |
W/LB 2 - RH turn indicator |
→ |
14 |
W/LB 2 - RH turn indicator |
| 3B |
LG/W 3 - LH turn indicator |
→ |
15 |
LG/W 3 - LH turn indicator |
| 6A |
DG/Y 11 - Tach - IDM from EEC |
→ |
16 |
DG/Y 11 - Tach - IDM from EEC |
| 3A |
T/W 87 - High Beam indicator |
→ |
17 |
LG/BK 12 - High Beam indicator |
| |
|
→ |
18 |
DG/W 150 - Speed Sensor VSS+ |
|
| |
Other wiring issues to deal with.
| Ranger connector |
|
|
| Location |
Wire color circuit # - description |
|
|
| 13B |
LG/R 904 Charge Indicator |
→ |
Connect
these wires together with a XXX ohm resistor to enable the charge
circuit. I am still researching this circuit. |
| 14B |
GY/Y 687 Power Run/Start for charge indicator |
→ |
| |
|
|
|
|
|
Fuel Sender
The TC cluster expects fuel sender values of 8-14 ohms
Full and 60-86 ohms Empty.
The 87 Ranger (gen I) EVTM does not give specific values
for the sender, but states: The fuel gage connects to a fuel gage sender.
The sender is a variable resistor connected to a float in the fuel tank.
When the fuel is low, resistance is high; when fuel is high, resistance is low.
On the next page of the manual, there is general testing for gages out of
calibration and states: Normal gage resistance is 10 to 14 ohms. Check
gage calibration with 10 ohm (high) and 73 ohm (low) resistors. If gage tests
within calibration, replace sender.
The 89 Ranger (gen II) EVTM does not give the specific
values, it states: The fuel gage is connected to the fuel gage
sender thru the slosh module. The sender is a variable resister connected
to a float in the fuel tank. When the fuel is low, resistance is high;
when the fuel is high, resistance is low. THE
EVTM IS WRONG!
The 1990 Ranger shop manual, group 13 reads: With
the sender float arm in the empty position, resistance should be 15 ohms (below
'E'). With the sender float arm in the full position, resistance should be
160 ohms (above 'F'). The fuel gauge should read empty at 22.5 ohms and
full at 145 ohms.
| Summary
of fuel sender values |
| |
TC sender |
83-88 Ranger (gen I) |
89-95 Ranger (gen II) |
| Full |
8-14 ohms |
10 ohms |
145 ohms |
| Empty |
60-86 ohms |
73 ohms |
22.5 ohms |
The OEM (mechanical) Instrument Voltage Regulator (IVR)
provides 5V of power to the Fuel, Oil and Temp gauges. This IVR is prone
to failure, so the IVR on the cluster is eliminated and 5V power for the gauges
is provided by a
solid state IVR.
Above is the cluster with LEDs for shift light and air-fuel meter.
