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M1009 Electrical Issues - 4x4 and Gen Idiot Lights

T

tjf1980

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Olathe, KS
Long story short, I sold my M1009 to a guy a few years ago. He was in way over his head with a military diesel and I bought it back last fall. He had replaced the alts, with the wrong ones and bang. Ruined two brand new alts.

I rebuilt them using the correct parts and cases. Alt 1 is good and charging.

My current issue is none of my idiot lights on left side of the inst cluster are working. Nothing over there lights up when key turned to run or while running.
Fuses all good and power to both sides. Instrument cluster circuit and connector are good. Bulbs all good.
Alt 2 isn't charging but I assume it's because the gen light isn't working?
Possible coincidence? Maybe the 4x4 switch is bad and on top of that there's still something wrong with the alt circuits? Should the oil pressure light come on when key is on?
Any common item that would cause all 4 of those lights to all not work? Anything else common that fails when the alts go boom? Fusable links? Relays?
What would be the next logical things to check?

Any help is appreciated. Thanks!
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Barrman

Barrman

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Giddings, Texas
Yes, the oil light should come on with the key and stay on until oil pressure is achieved. The test for it is to ground the lead to the sensor with the key on and the light should come on.

I don’t remember and didn’t look it up, but I think the 4x4 light also glows when its leads are connected.


The ALT lights are part of the exciter wire circuit. If they don’t work, the alternator will not turn on. With the engine running you can try jumping the brown wire on the alternator from the red wire next to it on the alternator plug. That should turn it on. Of course, a volt meter on the rear battery is how you are supposed to test it working. But, a screwdriver at the rear bearing cover will tell you as well. A working alternator will be magnetized there and you will feel the screwdriver get pulled in.

I think though that your idea about the left side of the cluster being bad is closer to the problem. I have had trouble in the past with the big plug at the back of the cluster and the flexible circuit board contacts. I suggest taking the cluster out of the truck and if possible put power to every light and see if they work.

If that shows all the lights and circuits good then you are back to something on the truck side of things.
 
T

tjf1980

New member
2
1
1
Location
Olathe, KS
Barrman said:
Yes, the oil light should come on with the key and stay on until oil pressure is achieved. The test for it is to ground the lead to the sensor with the key on and the light should come on.

I don’t remember and didn’t look it up, but I think the 4x4 light also glows when its leads are connected.


The ALT lights are part of the exciter wire circuit. If they don’t work, the alternator will not turn on. With the engine running you can try jumping the brown wire on the alternator from the red wire next to it on the alternator plug. That should turn it on. Of course, a volt meter on the rear battery is how you are supposed to test it working. But, a screwdriver at the rear bearing cover will tell you as well. A working alternator will be magnetized there and you will feel the screwdriver get pulled in.

I think though that your idea about the left side of the cluster being bad is closer to the problem. I have had trouble in the past with the big plug at the back of the cluster and the flexible circuit board contacts. I suggest taking the cluster out of the truck and if possible put power to every light and see if they work.

If that shows all the lights and circuits good then you are back to something on the truck side of things.
Click to expand...
Barman, Yes I did check the inst cluster circuit and it has continuity. I was honestly hoping to find a short in the printed circuit but all is good there. I even applied 12v to it and the lights all worked as expected. Tells me it's something outside of the inst cluster and fuse panel. Just not totally sure where to check from there.

That sounds like a good plan next to jump the exciter wire and check alt 2 voltage.

The inst cluster plug sure looks clean and in working order. I previously years ago rehabbed the whole cluster and still looks fresh. I even traced the circuit path for the 4x4 light and was checking the plug with a test light while shifting in and out of 4x4. No response. So that tells me it's something outside of the inst cluster.

Still not sure if they are related but seems too much of a coincidence none of the 4 idiot lights work.

Appreciate the input, keeps me thinking!
 
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