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 Instrument Cluster Upgrade
Document Description

Firstly - A BIG THANKYOU GOES OUT TO THE FOLLOWING -
Adam [Send me your full name so as I can give you proper credit !] for the pictures of the AU Series I Futura, and the AU Series I Fairmont Instrument Clusters
Chris Wallis [aka TOXIC] for the Pictures of the AU Series II XR Tickford Clusters

PLEASE NOTE : THESE PICTURES ARE COPYRIGHTED BY THE ABOVE OWNERS, AND CANNOT BE REPRODUCED WITHOUT THEIR EXPRESS PERMISSSION

A big thankyou guys, as without your help, this Doco would not be possible !
Finally, we are still looking for pictures of the following cluster Models -
AU Series I, Mid-Sports-Tickford Cluster (As fitted to XR6, and XR8 Models)
AU Series II Base Cluster (As fitted to Forte and Futura models)
AU Series II High Cluster (As fitted to Fairmont, Fairmont Ghia, Fairlane, and LTD Models)

This Document Describes the differences between various models of Instrument Clusters fitted to the AU Series 1 model 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.

The AUI series of Falcons brought with them four models of Instrument Clusters that were fitted to the various models of these vehicles.
These clusters all had Red Long style Needles, Orange Segment LCD Displays, and Black Background Faces
With the advent of the AU Series II Falcons, these Instrument clusters were revised with the following changes
Inverted LCD Panels, with White Illumination, Short Style Red Needles, Blue Coloured Faces for Tickford Models, Removal of the secondary Gear Position LCD Panel on High series clusters.

The Following Images of Clusters have been taken from various AU Models, and include,
  • The Standard Cluster (Low Series) as fitted to Gli, and Futura Models
  • The Sports Series Instrument Cluster (Mid-Tickford Series), as fitted to XR6, and XR8 Models
  • The High Series Instrument Cluster as fitted to the Fairmont, Fairlane, and LTD Models.

    Please Note : At Present the Wiring information is only applicable to the AU Series I Model Falcons.
    The AUII and AUIII Series have entirely different wiring when compared to the AUI Models
  • AU Series I - Base Series Cluster

    The AU Series 1 Falcon Base Series Cluster, as Fitted to GLi, and Futura Models
    The AU Base Series Cluster has the following Features
  • White Illumination, with Orange Coloured Cluster Needles
  • 220Km Electronic Speedo, with 20Km Speed Numeral Markings, and 5Km Line Markings
  • 7000 RPM Tacho, with 1000RPM Numeral Markings, and 250RPM Line Markings
  • Fuel Guage with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Guage, with high Temperature warning Lamp
  • Seatbelt Warning Lamp
  • Smartlock(Early Build Series 1) or Smartsheild (Late Build Series 1) Warning Lamp
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • ABS Warning Lamp
  • Turn Signal and High Beam Indicators
  • Lights on with Ignition off warning lamp (ON LCD Panel)
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Low Coolant Warning Lamp
  • Door Ajar Warning Lamp
  • Air Bag Fault indicator
  • Auto Transmission economy mode indicator
  • Cruise Control Indicator (where fitted)
  • Speed Warning Indicator and Buzzer
  • Distance to Empty Calculation and Warning
  • AU Chaser (Police) Cluster

    The AU Police Instrument Cluster
    The AU Chaser (Police) Series Cluster is a special issue cluster, and was made only available to Police issue AU Forte and XR Falcons.
    These Falcons had a number of upgrades made to the vehicle, with the Instrument Cluster being one of them.
    The Chaser (police) Cluster is based on the Low Series (Forte, Futura) Instrument Clusters, but with 2 very important modifications made to them.
  • The AU Police Cluster has a Speedo Calibration Feature, which allows the user to calibrate the speedo, and Odometer Readings with a percentage error.
    These Clusters are very rare, and are a much sought after item because of this calibration feature, as it makes wheel, tyre, and Diff Changes very easy in regards to calibrating the Speedo.
    The Calibration range can be made between +-10%, with 0.5% increments.
  • The Speedo has Markings every 2Kmph, for improved speedo accuracy.
    The Calibration Mode can be entered using the following proceedure,
  • AUI - With the Ignition On, hold the reset shaft in for 5 seconds and then release
  • AUII & AUIII - While Holding the reset shaft in, turn the ignition On and continue to hold the reset shaft in until the cluster enters calibration mode. This will typically occure after approximately 5 seconds.
    Much like the AU Low Series Instrument Cluster, the AU Chaser (Police) Cluster has the following features
  • White Illumination, with Red Coloured Cluster Needles
  • 220Km Electronic Speedo, with 10Km Speed Numeral Markings, and 2Km Line Markings
  • 7000 RPM Tacho, with 1000RPM Numeral Markings, and 250RPM Line Markings
  • Fuel Guage with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Guage, with high Temperature warning Lamp
  • Seatbelt Warning Lamp
  • Smartlock(AUI Early Build) or Smartsheild (AUI Late Build Onwards) Warning Lamp
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • ABS Warning Lamp
  • Turn Signal and High Beam Indicators
  • Lights on with Ignition off warning lamp (ON LCD Panel)
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Low Coolant Warning Lamp
  • Door Ajar Warning on LCD Panel (Non Door Specific)
  • Air Bag Fault indicator
  • Auto Transmission economy Mode Indicator
  • Cruise Control Indicator (where fitted)
  • Speed Warning Indicator and Buzzer
  • Traction Control Indicator (Where Fitted)
  • Low Windscreen Washer Fluid Warning
  • Distance to Empty Calculation and Warning
  • AU Mid Series (Sports XR) Cluster

    The AUII XR Instrument Cluster, as fitted to XR6 and XR8 Models The AUII XR Instrument Cluster, Illuminated
    PLEASE NOTE : The above cluster is an AU Series II - NOT an AU Series 1 XR Cluster !
    The AUI Mid Series Cluster (XR Sports Cluster) on the AUI Models, is a combination of the High Series Instruments, and the Base Series LCD Panel
    The AUII and AUIII Mid Series Instrument Cluster (XR Sports Cluster is the same as the High Series Cluster, with exception to the Door Ajar Warning, which will Illuminate all the Doors on the Display, if any door is opened.
    In addition to these features, the XR Cluster features a Unique Tickford emblem located on the Speedo, above the Needle.
    The AU Mid Series Cluster has the following Features
  • White Illumination, with Orange Coloured Cluster Needles
  • Tickford Logo Located on the Speedo Dial, above the speedo Needle
  • 240Km Electronic Speedo, with 20Km Speed Numeral Markings, and 5Km Line Markings
  • 7000 RPM Tacho, with 1000RPM Numeral Markings, and 250RPM Line Markings
  • Fuel Guage with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Guage, with high Temperature warning Lamp
  • Battery Voltage Guage, Ranging from 10 to 16 Volts
  • Oil Pressure Guage
  • Seatbelt Warning Lamp
  • Smartlock(AUI Early Build) or Smartsheild (AUI Late Build and onwards) Warning Lamp
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • ABS Warning Lamp
  • Turn Signal and High Beam Indicators
  • Lights on with Ignition off warning lamp (ON LCD Panel)
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Low Coolant Warning Lamp
  • Door Ajar Warning on LCD Panel (Non Door Specific)
  • Air Bag Fault indicator
  • Auto Transmission economy Mode Indicator
  • Transmission Gear Position Indicator on LCD Panel (AUII-AUIII Models)
  • Cruise Control Indicator (where fitted)
  • Speed Warning Indicator and Buzzer
  • Traction Control Indicator (Where Fitted)
  • Low Windscreen Washer Fluid Warning
  • Distance to Empty Calculation and Warning
  • AU (High Series) Cluster

    The AU Series I High Series Cluster, as fitted to Fairmont, and Ghia models
    The AUI High Series Cluster (Fairmont, Fairlane, LTD Cluster) Uses the same shape Instrument Dials as the Mid Series Cluster, but has a unique LCD Panel, that includes a Door ajar, Boot open, and Fuel Flap Open Warning.
    This warning system utilises a Diagram of a sedan, and shows which door, (Driver's, Passenger, and Back Doors, indepentant of each other, much the same wasy as the EA-ED-EF-EL High Series Instrument Clusters Door Ajar Warning system works.
    The AUII and AUIII High Series Instrument Cluster has the Automatic Gear Position located on the main LCD Panel, whereas the Series 1 Models had this display on the Speedo Instrument Guage.
    The AU High Series Cluster has the following Features
  • White Illumination, with Red Coloured Cluster Needles
  • 220Km Electronic Speedo, with 20Km Speed Numeral Markings, and 5Km Line Markings
  • 7000 RPM Tacho, with 1000RPM Numeral Markings, and 250RPM Line Markings
  • Fuel Guage with Electronic Dampening with Low Fuel Warning Lamp
  • Temperature Guage, with high Temperature warning Lamp
  • Battery Voltage Guage, Ranging from 10 to 16 Volts
  • Oil Pressure Guage
  • Seatbelt Warning Lamp
  • Smartlock(AUI Early Build) or Smartsheild (AUILate Build and ownards) Warning Lamp
  • Park Brake Warning Lamp
  • Brake Fail Warning Lamp
  • ABS Warning Lamp
  • Turn Signal and High Beam Indicators
  • Lights on with Ignition off warning lamp (ON LCD Panel)
  • Low Oil Warning Lamp
  • Alternator Warning Lamp
  • Low Coolant Warning Lamp
  • Door Ajar Warning on LCD Panel (Door Specific)
  • Boot Open Warning (Sedan Only)
  • Air Bag Fault indicator
  • Auto Transmission economy Mode Indicator
  • Transmission Gear Position Indicator on seperate LCD Panel under speedo (AUI Models)
  • Transmission Gear Position Indicator on LCD Panel (AUII-AUIII Models)
  • Cruise Control Indicator
  • Speed Warning Indicator and Buzzer
  • Traction Control Indicator (Where Fitted)
  • Low Windscreen Washer Fluid Warning
  • Distance to Empty Calculation and Warning
  • Upgrading and swapping Instrument Clusters

    With exception to the Low Series Instrument cluster, it is possible to change between different Cluster models rather painlessly.
    All AU Series 1 Instrument Clusters use the same Electrical Connectors, (2 Connectors), but for the Low Series Cluster, some wires need to be moved around for the Left Hand Side Connector, In order for the Mid/High Series Cluster to function correctly.
    The Mid, Police and High Series Clusters all use the same connectors, same Bulb holders, same needles, and Depending on the Cluster Series, very similar/Same circuit boards.
    The AU Series I Mid and High Series Clusters use a different LCD Panel, but the wiring (With Exception to the extra Door Outline Wiring) is 100% Compatible.
    That is, if swapping a Mid Series Cluster for a High Series Cluster, you will need to run new wiring from all 4 Doors, to the Instrument Cluster Wiring Harness

    Some important steps to watch out for when doing an Instrument Cluster conversion will include,
  • 1. The Odometer Reading will need to be changed. (Remember your Pinkslip will have this reading on it from your previous years Registration - There is a $10,000 fine for Fraudulantly Winding Back your Odometer Reading.)
  • 2. If Upgrading from a Base Instrument Cluster, The Oil Pressure Switch will need to be replaced with an Oil Pressure sensor.
  • 4. If adding the Low Windscreen Washer Level Warning Lamp, a new Washer Bottle, with Level sensor, and an extra line will need to be added for the Warning to work.

    Some Common misconceptions with the Ford Falcon series Clusters include
  • 1. The Odometer Readings can be swapped, changed or kept. The Odometer Reading is held within the Instrument Cluster, not within the EEC-V Engine Management, nor does the Instrument Cluster have a Backup Memory, or a Tamper-proof mechanism to deter Odometer Fraud !
  • 2. There is no Electrical, or Calibration Difference within the speedo sections of the cluster, in terms of different Factory fitted Diffs, wheel, and Tyre Ratios. Changing Clusters will not alter the Factory speedo readings.
  • 3. It is not possible to use an XR Series II Face, on a Low or High Series Cluster ! This is due to the Maximum speed on the cluster face, which means that the speed increments are slightly compressed.
    The XR Series Cluster circuit board takes this compression in consideration when moving the speedo needle, and as such, you would need to swap the complete cluster over to use the XR Face.

    Wiring changes required when fitting a Mid/High Series Cluster to a Forte/Futura Model Falcon.
    Although the Mid and High Series Clusters will simply plug in, and A L M O S T function, there a re a few changes you will need to make, in order to get the Cluster to function correctly.
    These changes are needed in order for the following to function,
  • Dial Illumination with Park Lamps On
  • The ABS Warning Lamp to Illuminate correctly
  • The Right Hand Side Indicator Lamp to function Correctly

    The following wires need to be moved around, in order for the Mid/High Cluster to function correctly,
  • 1. The Park Lamp Dial (+ Positive) Illumination needs to be moved from Pin 13 to Pin 2.
  • 2. The Dial Negative Dimmer Illumination needs to be moved from Pin 21 to Pin 3.
  • 3. The ABS Warning Lamp Wire needs to be moved from Pin 8 to Pin 23
  • 4. The R.H. Side Indicator wire needs to be moved from Pin 19 to Pin 26

    Please Note : In addition to these changes, you will need to also change the Oil Warning Switch, to an Oil Pressure sender unit, and also swap the Odo Reading. (See Below for further details on how to do this)
  • Swapping Odometer Readings

    Obviously, when swapping Instrument clusters, you will want to keep the same Odometer Readings for your vehicle.
    Because the EF and EL series vehicles 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 upgradable 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.
    As was previously mentioned, this chip is surface mounted, that is you will need special tools in order to remove it.
    It is this chip that stores the Odometer, as well as other readings.
    When swapping Instrument Clusters, you will need to De-Solder this chip, and swap it from your Original Instrument Cluster, to your new Instrument Cluster.
    WARNING : I take no responsibility for any Damage that may be caused through any actions that are taken, that are directly, or Indirectly related to the information provided herein !
    This is a small, delicate, and heat sensitive chip, and as such, is very suceptable to permenant damage, which WILL if damaged, render the instrument cluster USELESS !
    Under no circumstances will Matthew I Jones be held responsible for any such damage.
    Remember, this site is provided to you, free of charge, and it is up to yourself to correctly determine what modifications can be safely conducted by yourself !
    Adding an Oil Pressure Sensor

    Because the Low 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 or High series Instrument cluster is used with an Oil Pressure switch, the Oil Pressure guage 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 guage.
    The Mid and High 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 Information for the AU Series I Instrument Clusters
    AUI Falcon Low Series Instrument Cluster (Forte/Futura Models)
    Left Hand Side Instrument Cluster Connector
    Pin 1 Not Used    
    Pin 2 Not Used    
    Pin 3 Not Used    
    Pin 4 Not Used    
    Pin 5 Not Used    
    Pin 6 Not Used    
    Pin 7 Spare LED #5 Switch to ground or Open Circuit  
    Pin 8 ABS Warning Lamp Open Collector Orange/Black
    Pin 9 Heated Backlight (Rear Window Demister) +12V Light Green/Black
    Pin 10 Alternator Fail Open Collector Grey/Red
    Pin 11 L.H. Blinker +12V Light Green / White
    Pin 12 High Beam Warning Lamp +12V Light Green / Black
    Pin 13 Park Lamps (+ Dial Illumination) +12V On Brown
    Pin 14 Brake Fail 0V On Pink / White
    Pin 15 SmartLock/Sheild LED Ground On Dark Blue / Light Green
    Pin 16 Spare LED #2 +12V On  
    Pin 17 Not Used    
    Pin 18 Park Brake warning lamp 0V On Red / Orange
    Pin 19 RH Blinker +12V On White / Light Blue
    Pin 20 Spare LED #3 +12V On  
    Pin 21 Dial Illumintation Negative (Dim) 0V Bright - 10V Dim Light Blue / Red
    Pin 22 Air Bag Warning Lamp Open Collector Black / Yellow
    Pin 23 Not Used    
    Pin 24 Not Used    
    Pin 25 Not Used    
    Pin 26 Not Used    
    Pin 27 Not Used    
    Pin 28 Not Used    
    AUI Falcon Mid / High Series Instrument Cluster (XR/Fairmont/Ghia/Fairlane/LTD/Tickford Models)
    Left Hand Side Instrument Cluster Connector
    Pin 1 Autolamp off Overide (High Only) ADC Input  
    Pin 2 Park Lamp (Dial) Positive Illumination +12V Brown
    Pin 3 Dial Illumination (Negative) Dimmer PWM From BEM - 0V Bright - 10V Dim Light Blue / Red
    Pin 4 Fuel Flap open Input (High Series Only) Resistance 180 Ohm Open - 1380 Ohm Closed Orange
    Pin 5 Right Rear Door Switch (High Series Only) Switch to ground open Black / Orange
    Pin 6 Front Left Passenger Door Switch (High Series Only) Switch to Ground open Brown
    Pin 7 Rear Left Door Switch (High Series Only) Switch to ground open White / Pink
    Pin 8 Boot Lid Open (High Series Only) Switch to ground open White / Pink
    Pin 9 Heated Backlight (Rear Window Demister) +12V Dark Blue
    Pin 10 Alternator Fail Open Collector Light Green / Red
    Pin 11 L.H. Blinker +12V Light Green / White
    Pin 12 High Beam Warning Lamp +12V Light Green / Black
    Pin 13 Spare LED #2 +12V On  
    Pin 14 Brake Fail 0V On Pink / White
    Pin 15 SmartLock/Sheild LED Ground On Dark Blue / Light Green
    Pin 16 Spare LED #4 +12V On  
    Pin 17 Door Ajar Output (High Series Only) Open Collector  
    Pin 18 Park Brake warning lamp 0V On Red / Orange
    Pin 19 Not Used    
    Pin 20 Spare LED #5 +12V On  
    Pin 21 Spare LED #3 0V Bright - 10V Dim  
    Pin 22 Air Bag Warning Lamp Open Collector Black / Yellow
    Pin 23 ABS Check Open Collector Tan / Light Blue
    Pin 24 Not Used    
    Pin 25 Not Used    
    Pin 26 R.H. Blinker   White / Light Blue
    Pin 27 Not Used    
    Pin 28 Not Used    
    AUI Falcon Low/Mid/High Series Instrument Cluster
    Right Hand Side Instrument Cluster Connector (Common for all models - J2)
    Pin 1 Power Ground Ground Black
    Pin 2 Signal Ground Ground Black / Light Green
    Pin 3 Low Coolant Resistance Yellow / Red
    Pin 4 Ignition Power +12V with Ignition On Red / Dark Green
    Pin 5 Low Oil Warning (Low Series)
    Oil Pressure (Mid/High Series)
    0V Low Oil
    0V Low Pressure, 12V High Pressure
    White / Red
    Pin 6 Door Ajar (Low / Mid Series)
    Front Drivers Door open (High Series)/TD>
    Ground when any door open
    Ground when Drivers door open
    Black / Light Blue (Low/Mid)
    White (Hi)
    Pin 7 Fuel Sender Resistance Yellow / Dark Green
    Pin 8 Spare (Low and Mid Series)
    MDC Tx Data (High Series)
     
    Output to Trip/Climate Control Center

    Orange
    Pin 9 Spare (Low and Mid Series)
    MDC Rx Data (High Series)
     
    Input from Trip/Climate Control Center

    Yellow
    Pin 10 Low Washer Fluid Input Switch to ground for low fluid Pink / Yellow
    Pin 11 Spare (Low Series)
    Traction Control Warning Lamp (Mid/High Series)/TD>
     
    Ground to Illuminate

    Dark Blue
    Pin 12 Airbag Audible warning Open Collector Orange / Yellow
    Pin 13 EEC V Data (Serial) Open Collector (Sheilded Data Line)
    Pin 14 Diagnostic ISO Serial I/O Open Collector Pullup Batt Not Connected
    Pin 15 LCD Dimmer Input 2 Stage (Low Series)
    LCD Dimmer Input Variable (Mid/High Series)
    Ground/Resistance
    Open Collect PWM Output from Bem
    White
    Pin 16 Tacho Input Pulsed from 0V to +12V White / Pink
    Pin 17 Speed Input Pulsed from 0V to +12V Light Blue / White (Hi) / White (Low)
    Pin 18 Speed Output Pulsed form 0V to +12V White
    Pin 19 Speedo Sender power supply +8.2V Red (Hi) / Yellow/Light Green (Low)
    Pin 20 Battery Power +12V Black / Orange
     
     Document Summary
     
    Document description: Upgrading the Instrument Clusters for AU Series 1 Falcons
    Document written by: Matti on 17 2002>, Copyright © 2005 Matti, all rights reserved.
    Document revised: 19 2005 - Revision 2.0
    Document views: 35878 since 17 2002



     

     

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