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  4. Rod Racer

    Power Steering Box Adjustments XA - XG

    I'll do this on the XF's PS box to see if it comes good, only then will I replace it.
  5. the miracle stick mechanic

    Power Steering Box Adjustments XA - XG

    Notes: There is absolutely no need to dismantle the steering box unless oil leaks are occurring . After removal, rotate from lock to lock until ALL the oil is expelled to prevent fluid friction affecting the adjustments . Removing preloads 1. Remove allen key plug #5 and undo the output shaft adjuster 2-3 turns anti-clockwise. 2. Loosen the locknut and undo the input shaft bearing adjuster #26 by 1/2 to 1 turns anti-clockwise. 3. Loosen the locknut and undo the power steering piston adjuster #10 by 1/2 to 1 turns . Now you are ready to make the three adjustments Note: The aim is to create some binding and friction as the input shaft passes through the straight ahead position from each side. But this friction should only be created by the final adjustment made on the output shaft. This helps the car to maintain a straight line course and prevents the steering from wandering . 1. The three adjustments are to be made while the steering is turned about a 1/4 turn away from the straight ahead position . This is because the steering box is designed to have freeplay when the steering wheel is turned away from the central position . 2. The steering box must be removed from the car to make the adjustments because the first two adjustments are critical and must not bring about any friction as the steering box passes through the straight ahead position . You will not feel the friction with enough sensitivity if you are turning the steering wheel with the box installed. This must be done by feeling with your hand as you rotate the input shaft one quarter turn either side of the straight ahead position (with the flexible coupling fitted ). 3. The three adjustments are the input shaft (the shaft connected to the steering wheel ), the power steering piston, and finally the output shaft (the shaft connected to the pitman arm) 4. The adjustments are made in the order mentioned directly above in point three. 5. The adjustments are made in this order because only the third and final adjustment made on the output shaft should introduce any friction as the input shaft passes through the straight ahead position 6. The input shaft adjustment is made the exact same way a wheel bearing is adjusted . ie. Tighten/preload the bearing adjustment nut and then back off slightly ensuring no friction is felt as the input shaft is turned after adjustment . 7. The power steering piston is adjusted clockwise until friction occurs as the box passes through the centre position . The adjustment must be made with the box turned 1/4 turn off centre in either direction . Then back it off until the friction is completely removed. But only just removed . 8. Finally, tighten the output shaft adjuster until a little bit of binding occurs as the box passes through the centre position . Make the adjustment whilst the box is turned 1/4 turn off-centre. You should be able to turn the box through the centre position using your hand to rotate the flexible coupling. It shouldn't be easy to turn through the centre position . And it shouldn't be hard to turn through the centre position . Find the middle ground .
  6. Earlier
  7. xhadyboy

    XE S PAK seat material

    I needed some seat material for my XH XR6 . I got referred to Charlie at C&N Trimming in5 Douglas Rd North Sunshine.93110722 He had both the different outside and inside trim's. He said he had all kinds of NOS bits and pieces , so maybe worth a call. Then i asked him about some Sierra Tan S pack material for my XE ,he said "except that".
  8. ESP302WA

    XE S PAK seat material

    I've just ordered the black trim from Global so get hold of Ben quick while they still have it.
  9. they definitely did, but i can't find a pic on google either
  10. Hey team, Can someone tell me if rear XF calipers came with standard shims to reduce pad movement? My google/ Ebay searching would suggest not.... My inner pads are moving (up and down) in the caliper, causing an annoying rattling/ clacking sound. Before the brake guy attempts to fabricate some thought I'd check my options. Also, does anyone have a line on new anti rattle clips? I'm struggling to track down used ones on this side of the ditch and (again) before I have one made up, wanted to check if there were aftermarket ones lurking somewhere. Again, google search would suggest not. Cheers, Wade.
  11. this should be a warning to anyone who's bought one, considering buying or has currently chewed out their "spud" adapter with a Barra ZF6 speed into landcruiser..
  12. 408WPN

    XG or EB S Pack Dash to XF wiring chart.

    Awesome M8,thanks alot
  13. deankxf

    XG or EB S Pack Dash to XF wiring chart.

    Yep that's the one. And on the passenger side of an ohc six engine block near the dizzy if you are finding one from a wreckers or donor car. Be aware the base models will be a switch on/off for the light. The s pack etc are a bigger unit that varies the guage
  14. I know its an old thread, but how did you go with the exhaust and tank? I've got a cover i picked up and was hoping to see if you figured out a way to have a tank and the twin exhaust?
  15. 408WPN

    XG or EB S Pack Dash to XF wiring chart.

    Thanks Dean, so am I correct in thinking the oil sender is the thing screwed into the top of the engine block behind the intake manifold on 351c
  16. deankxf

    XG or EB S Pack Dash to XF wiring chart.

    @Vannin hasn't logged in on here since 2013, so unlikely to respond. what I've mentioned above covers your questions generally. oil pressure sender to suit your cluster (EA to ED, XG XH sports clusters) fuel gauge @Crazy2287 may have some input if still playing with these cars.
  17. 408WPN

    XG or EB S Pack Dash to XF wiring chart.

    Vannin,receiving over. Hey John, super old post but could you email me particulars on XG Dash cluster conversion to XF, especially on regards to fuel sender & perhaps oil sender. My car is 1985 GL, engine swap to 351c. Cheers Andy thjsandy@yahoo.com.tw
  18. SPArKy_Dave

    Xf ute front suspension query

    Swaybar Link Pins... Early XF's incl XD/XE etc, use a bolt. Later XF's used the EA style link pins with a thread/nut at each end. I've never seen the EA style links available aftermarket, only the bushes. U can get universal threaded links, with inner nuts to adjust, rather than a spacer, Or repro bolt style link pins with spacer - same as XA/XB's, mustangs, etc.
  19. Does anyone know whether xh ef or el’s use the same lower arm to stabiliser bar spacer studs (ellery calls them stabiliser bar spacer studs, others sometimes call them rods). P219-221 of the ellery manual EP.F5 its the double nutted small rod that sits between the (stamped on an xf) lower susp arm and front stabiliser bar. xf utes use a threaded at both ends stud, xe’s ive come across seem to use a bolt threaded at one end, ef/el’s serm to have a stud the same dimension but thicker. the ones on my ute are absolutely munted. Ex farm ute it apparently was used as a garden feature and the studs are badly corroded. Csnt find a part number, or any wrecks intact enough, so last resort is to see if ef, el, xh are compatible. xf used stamped lower arms, ef el xh use cast arms
  20. deankxf

    EL Cluster into XH?

    Oil sender on e series engine is passenger side but closer to the dizzy. Could be difficult to get your hand in there (from underneath is Probably the only way)
  21. SPArKy_Dave

    EL Cluster into XH?

    Fairlane/LTD aka high-series clusters, are quite different again Passenger side of the engine block I believe?
  22. deankxf

    Adjusting handbrake at rear caliper

    apologies for the late reply sorry My brain is a bit fried lately, but to put it simply for you. * there's no adjustment on the caliper. so you can rest assured if the piston wound in enough to fit the pads and mount to the diff over the disc it's good enough. then it says to press the brake pedal a few times (this will push the pads hard against the disc ) then it says to adjust the U shape thing under the drivers seat(under the car) so you have the caliper levers not quite touching the stops. (I've never checked this before.. doubt it matters, but there might be a reason, even if it's to stop wear on the caliper body? that's it. good to go.
  23. waderobertson

    Adjusting handbrake at rear caliper

    That's what the manual says @deankxf. The hand brake is working fine, the arms on the rear of the caliper aren't seized (you can activate them with your hand when everything is connected up) and the cable is adjusted properly. I guess my question is more to do with setting the caliper itself before refitting, connecting handbrake and build pedal pressure. When I have wound the piston back in to refit pads I haven't touched the mechanism on the back of the caliper that the handbrake levers connect to, you know, the ones that have the rubber seal around them and the nut that holds the lever winds in to. You can wind these mechanisms in and out with a crescent and was wondering if they needed to be adjusted/ set a specific way (i.e. wound right out till you feel resistance? Does it even matter?) in tandem with winding the piston in to fit new pads. Is there a trick/ step I've missed in fitting the pads that I haven't got quite right? I could have a rotor issue or piston may be playing up, but before I head down those paths I just want to make sure it's not a simpler fix.
  24. XF EDDIE

    EL Cluster into XH?

    Thanks for the rundown. I'm pretty sure its not a fairlane cluster but ill just plug it in and see what happens. Also is the oil pressure sender in the same position as on the crossflows?
  25. Document Description This Document Describes the differences between various models of Instrument Clusters fitted to the EF/EL/NF/NL/DF/DL Series Falcons. It also has information on Upgrading an Instrument Cluster, modifications that need to be made, wiring information, swapping odometer readings, and some points to watch out for when performing these upgrades. With the EF series of Falcons (and Derivatives), there were four models of Instrument Clusters that were fitted to these vehicles. Theses Clusters Featured white Needles, with White Illumination, LCD based Odometers, Seat Belt Warning, and a Unique Diagnostic Mode With the Advent of the EL, all these clusters were revised to give a cleaner look, with Orange Needles, Less "Tick Lines" on the Speedo and Tacho, and a new Fuel Door Release Indicator. A new Cluster was also added to the range, which was fitted to the XR (Tickford) series of Vehicles. This new cluster is exactly the same as the Fairmont Mid Series Cluster, with the exception of a Tickford Logo being placed on the Tacho Section. The Following Images of Clusters have been taken from various EF/NF/DF Models, and include, NF Fairlane Instrument Cluster (High Series) as fitted to Fairlane, and LTD Models EF Chaser (Police) (Mid Series Special) Instrument Cluster, as fitted to ex Police Pursuit Models EF Sports Cluster (Mid Series) Instrument Cluster, as fitted to Fairmont, Fairmont Ghia, XR6, XR8 models EF Standard Cluster (Low Series) Instrument Cluster, as fitted to Gli, and Futura Models NOTE : If fitting Fairmont/Fairmont Ghia Instrument Cluster to a GLi/Futura/XR Model, it will be necessary to add a Resistor to the Instrument Cluster Circuit Board, in order for the LCD Backlighting to function correctly. Please see below for further information regarding this A Big thankyou goes out to WAYNE for Discovering this Interesting Quirk with the EL Clusters, and for working out how to fix this problem ! EF Base Series Cluster The EF Base Series Cluster has the following Features White Illumination, with White Cluster Needles 220Km Electronic Speedo, with 10Km Speed Numeral Markings, and 5Km Line Markings 6000 RPM Tacho, with 1000RPM Numeral Markings, and 500RPM 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 Park Brake Warning Lamp Brake Fail Warning Lamp Turn Signal and High Beam Indicators Lights on with Ignition off warning lamp and Tone Low Oil Warning Lamp Alternator Warning Lamp Low Coolant Warning Lamp (Fitted to Futura and Police/Taxi Pack Models Service Due Spanner Warning Air Bag Fault indicator ABS Fault Indicator (where fitted) Auto Transmission economy mode indicator Cruise Control Indicator (where fitted) Spot Lamps Indicator (there, but not wired up). Diagnostic Mode EF Mid Series Cluster The EF Mid Series Cluster is similar to the EF Base series Cluster, and has the following extra Features Oil Pressure Gauge Battery Voltage Gauge Low Windscreen Washer Fluid In addition to these features, the Mid Series Cluster has the following Features that are common with the Base Series Cluster. White Illumination, with White Cluster Needles 220Km Electronic Speedo, with 10Km Speed Numeral Markings, and 5Km Line Markings 6000 RPM Tacho, with 1000RPM Numeral Markings, and 500RPM 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 Park Brake Warning Lamp Brake Fail Warning Lamp Turn Signal and High Beam Indicators Lights on with Ignition off warning lamp and Tone Low Oil Warning Lamp Alternator Warning Lamp Low Coolant Warning Lamp (Fitted to Futura and Police/Taxi Pack Models Service Due Spanner Warning Air Bag Fault indicator ABS Fault Indicator (where fitted) Auto Transmission economy mode indicator Cruise Control Indicator (where fitted) Spot Lamps Indicator (there, but not wired up). Diagnostic Mode EF Chaser (Police) Cluster (Part Number 94DA-10849-BB) The EF Chaser (Police) Series Cluster is a special issue cluster, and was made only available to Police issue EF 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 Mid Series Instrument Cluster, but with 2 very important modifications made to it. Instead of a Diagnostic Mode that is available with all other EF series Clusters, the EF 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 a re 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. Much like the EF Mid Series Instrument Cluster, the EF Chaser (Police) Cluster has the following features Oil Pressure Gauge Battery Voltage Gauge Low Windscreen Washer Fluid White Illumination, with White Cluster Needles 220Km Electronic Speedo, with 10Km Speed Numeral Markings, and 2Km Line Markings 6000 RPM Tacho, with 1000RPM Numeral Markings, and 100RPM 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 Park Brake Warning Lamp Brake Fail Warning Lamp Turn Signal and High Beam Indicators Lights on with Ignition off warning lamp and Tone Low Oil Warning Lamp Alternator Warning Lamp Low Coolant Warning Lamp (Fitted to Futura and Police/Taxi Pack Models Service Due Spanner Warning Air Bag Fault indicator ABS Fault Indicator (where fitted) Auto Transmission economy mode indicator Cruise Control Indicator (where fitted) Spot Lamps Indicator (there, but not wired up). NOTE : Diagnostic Mode is not available on the Police Instrument Clusters, as this mode is replaced by the Calibration Mode NF Fairlane (High Series) Cluster The NF Fairlane, and DF LTD Instrument Clusters (High Series) are very similar in layout, to the EF Series of Clusters, but unfortunately, very few parts are interchangeable between the two. These clusters feature Unique Background Lettering / Graphics, Needles, Bulb Holders, LCD Panel, and Warning Lamps. Other Features include Oil Pressure Gauge Battery Voltage Gauge Low Windscreen Washer Fluid Warning Lamp (On LCD) White Illumination, with White Cluster Needles 220Km Electronic Speedo, with 10Km Speed Numeral Markings, and 5Km Line Markings 6000 RPM Tacho, with 1000RPM Numeral Markings, and 100RPM 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 Park Brake Warning Lamp Brake Fail Warning Lamp Turn Signal and High Beam Indicators Lights on with Ignition off warning lamp and Tone Low Oil Warning Lamp Alternator Warning Lamp Low Coolant Warning Lamp Service Due Spanner Warning (On LCD Panel) Air Bag Fault indicator Lamp ABS Fault Indicator Lamp Auto Transmission economy mode indicator (On LCD) Cruise Control Indicator (On LCD) Check Suspension Warning Lamp Spot Lamps Indicator (there, but not wired up). Automatic Transmission Gear Position Indicator Vehicle Outline, with Door Ajar, Boot, and Fuel Flap Status Indicators (On LCD) Park Lamp Bulb Out Warning (On LCD) Brake Lamp Bulb Out Warning (On LCD) Diagnostic Mode Upgrading and swapping Instrument Clusters With exception to the NF Fairlane cluster, and fitting Fairmont Clusters to GLi/Futura/XR models, it is possible to change between different Cluster models rather painlessly. The Low, Mid and Police Clusters all use the same connectors, same Bulb holders, same needles, and very similar circuit boards / Needle Assemblies. NOTE : Fairmont, Fairmont Ghia, and EL-GT Clusters are missing 1 Resistor, that is used to allow LCD Illumination, with the Park Lamps on ! When fitting an EF/EL Fairmont, EF/EL Fairmont Ghia, or ELGT Instrument Cluster to an EF/EL GLi/Futura/XR model Falcon, you will Need to add this resistor for the LCD Panels to function correctly. Without this resistor, the LCD Panels (Clock/Trip Computer/Odometer/Climate Control) WILL NOT ILLUMINATE AT ALL WHEN THE PARK LAMPS OR HEADLAMPS HAVE BEEN TURNED ON !) NOTE : This resistor is not required when Fitting Fairmont/Fairmont Ghia/EL-GT/Fairlane/LTD Clusters to vehicles fitted with a High Series BEM (Fairmont/Ghia/EL-GT/Fairlane/LTD) Information for fitting this resistor (and the reasons behind it - are outlined below. Some important steps to watch out for when doing an Instrument Cluster conversion will include, 1. As stated above, when fitting a Fairmont/Ghia, or GT Cluster to a GLi/Futura/XR Model, you will need to add 1 Resistor to the Cluster Circuit Board - This procedure is outlined below 2. The Odometer Reading will need to be changed. (Remember your Pink slip will have this reading on it from your previous years Registration - There is a $10,000 fine for Fraudulently Winding Back your Odometer Reading.) 3. 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 Coolant Warning Lamp on Gli Vehicles, an extra wire, and a Coolant Sensor switch will need to be added. (Note All Clusters have the ability to display the Low Coolant Output). 5. 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. (Note All Clusters have the ability to display the Low Windscreen washer Level LCD Warning). Some Common misconceptions with the EF and EL series Clusters include 1. There is no difference with V8 and I6 Tacho sections ! - Don’t ask me why, but I definitely have a V8 Fairlane Cluster fitted to my EF, and it has an Inline 6 motor. The Tacho section on both the original, and Fairlane Clusters are within 20RPM tolerance of each other, throughout the entire rev range ! 2. 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 ! 3. 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. Adding the LCD Dimming Resistor A Big thankyou goes out to WAYNE for Discovering this Interesting Quirk with the Fairmont Clusters, and for working out how to fix this problem ! NOTE : When fitting a Fairmont/Fairmont Ghia/EL-GT Instrument Cluster to a GLi/Futura/XR Model, you will need to add 1 Resistor to the Instrument Cluster, in order for the LCD Panels to Illuminate correctly. Without this resistor, the LCD Panel(s) (Clock/Trip Computer/Climate Control/Odometer) will not Illuminate when the Park Lamps, or Headlamps have been switched on. The reason for fitting this resistor is Fairmont/Fairmont Ghia/EL-GT/Fairlane/LTD Model Falcons use the Body Electronics Module to Dim the LCD Panels, when the Headlamps are switched On. The Low and Mid Series Body Electronics Modules DO NOT HAVE THIS FACILITY. Fords Method of getting around this problem, was to fit a Resistor the Instrument Clusters for use in GLi/Futura/XR Models. This Resistor Feeds the Negative LCD Dimming Circuit, when the Park Lamps are on, and without it, the LCD Illumination Bulbs will not Illuminate. Please Note : Fitting this resistor does not apply when fitting an XR Cluster, to a GLi/Futura/XR Model Falcon. Finally, it is also worth noting that if fitting a GLi/Futura/XR clusters to a Fairmont/Fairmont Ghia/EL-GT, THIS RESISTOR WILL NEED TO BE REMOVED, and IN ORDER FOR THE Variable Dimming Function to work correctly with the LCD Panels. The location of this resistor is on the Instrument Circuit Board, and is located to the right of the RHS Instrument Cluster Connector. I.E. You will need to remove the Dials, and the circuit Board, flip the circuit board over, and solder the resistor in the position shown below. The Following Picture will give you a better idea of its location, The Resistor you will require is a 1Watt, 47 Ohm Resistor. The Colour Bands for this resistor are Yellow, Violet, Black, Gold (5% Tolerance, 4 Band type). Or for a 5 Band 1% Tolerance type resistor , the colour bands would be Yellow, Violet, Black, Black, Brown. Please note though, you will Require a 1Watt type Resistor, due to the currents required by the LCD Panels. The following are Catalogue Numbers for the above resistors, from various Electronics stores. Jaycar - Cat RR-2542 - 47R 1 Watt Carbon Film, 5% ($0.32 Pkt of 2) Dick Smith - R-1662 - Resistor 1W CF 47 Ohm, $0.10ea Adding the Resistor To do this, you will obviously need to remove the Instrument Cluster, and Disassemble. To Disassemble the Instrument Cluster, 1.Remove the Clear Lens, and Black Plastic Lens Holder by removing the 2 Torx Screws Located at the top of the instrument cluster. (NOTE : You do not require a Torx bit to do this, a flat-headed screwdriver is perfectly adequate.) 2.Unclip the Black Plastic Lens Holder by unclipping the 2 clips at the top, and 3 clips at the bottom of the cluster. 3.Remove the Plastic Masking Lens away from the Dial Faces 4.Remove the 2 Torx Screws, Located at the back of the Instrument Cluster (Near the Bulb Holders). These screws are used to hold the Dial Faces in place. 5.Once these screws have been removed, gently ply the Dial faces away from their respective metal clips. This requires some force to do this, but it is important that you pull the faces directly up and away from the circuit board ! Do not try and Wiggle the faces away from the board. 6.To remove the Cluster Circuit Board, Remove the 2 Torx screws located At the bottom of the Circuit Board. 7.Finally, lift the circuit board from the top, up, and out of the Cluster casing. (Pulling the bottom electrical connectors out from the Casing housing). Once the location is found, Heat up the Solder points outlined above, with a soldering iron, and attempt to clean the area of the solder. Below the solder are mounting holes for the resistor. Removing the Excess Solder will allow the resistor to be mounted by placing its legs through these holes. Once fitted, solder in place, and re-assemble the Instrument Cluster, and test. 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 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. This chip is located approximately 1cm to the right of the chunkiest chip, on the back of the Instrument Cluster Circuit Board. This is the same position as per the Low, Mid, and High Series Instrument Clusters. 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 susceptible to permanent 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 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. 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 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 Fog/Spot/Driving Lamp Warning Circuit A Big thankyou goes out to WAYNE for Discovering this Interesting Quirk with the EL Clusters, and for working out how to fix this problem ! The EF and EL series Instrument Clusters have the facility for a Fog/Spot/Driving Lamp Warning lamp, just above the Smartlock Warning Jewel, on the Instrument Cluster. Although the Facility is there, there are some additions that you will need to make to the Instrument Cluster, in order for this function to work. Firstly, a wire must be run to Pin 8, of the Left Hand Side (Passenger Side) Instrument Cluster. This wire Needs to have +12Volts running to it, in order for the Spot Lamp Warning Jewel to Illuminate. With most aftermarket Spot/Fog/Driving Lamp Circuits being triggered by switching +12V to the Spot Lamp circuit, this should not be a difficult task. Once this has been completed, you will need to add an extra Bulb, and Bulb Holder to the Instrument Cluster. There is a blanked out socket, just above the Smartlock LED. This socket is blanked out using a round paper sticker, and can easily be removed by simply peeling it off the circuit board. Once this sticker is removed, you will need to fit a Bulb Holder, complete with a Bulb to this empty socket. It is recommended that a 1.2Watt Globe is fitted to the Bulb Holder, though this is not terribly important (An increased Bulb Wattage will do no damage to the Cluster), you may find that at night time, 2Watt Bulbs may be too bright, and annoying. If you have an EF Model Instrument Cluster, then this is all that is required. And you are now ready to test the Spot/Fog/Driving Lamp warning jewels operation. Unfortunately, EL Model Instrument Clusters are a slightly different matter. These clusters are missing 1 Diode that is VITALLY important for the Spot Lamp Warning Jewel operation. For this circuit to function correctly, you will need to add 1 x 1N4004 Signal Diode to the circuit board, roughly behind the Battery Voltage Gauge. See the picture below for more details. To do this, you will obviously need to remove the Instrument Cluster, and Disassemble. To Disassemble the Instrument Cluster, 1.Remove the Clear Lens, and Black Plastic Lens Holder by removing the 2 Torx Screws Located at the top of the instrument cluster. (NOTE : You do not require a Torx bit to do this, a flat-headed screwdriver is perfectly adequate.) 2.Unclip the Black Plastic Lens Holder by unclipping the 2 clips at the top, and 3 clips at the bottom of the cluster. 3.Remove the Plastic Masking Lens away from the Dial Faces 4.Remove the 2 Torx Screws, Located at the back of the Instrument Cluster (Near the Bulb Holders). These screws are used to hold the Dial Faces in place. 5.Once these screws have been removed, gently ply the Dial faces away from their respective metal clips. This requires some force to do this, but it is important that you pull the faces directly up and away from the circuit board ! Do not try and Wiggle the faces away from the board. 6.To remove the Cluster Circuit Board, Remove the 2 Torx screws located At the bottom of the Circuit Board. 7.Finally, lift the circuit board from the top, up, and out of the Cluster casing. (Pulling the bottom electrical connectors out from the Casing housing). Once this has been completed, you will need to locate the position that the 1N4004 Diode will need to be soldered in place. The following image will assist you in this process. Once the location is found, Heat up the Solder points with a soldering iron, and attempt to clean the area of the solder. Below the solder are mounting holes for the Diode. Removing the Excess Solder will allow the Diode to be mounted by placing its legs through these holes. The Diode ! MUST ! sit in the direction where the Silver Band (the Cathode end) is towards the center of the circuit board. This is VITALLY IMPORTANT, as fitting the diode in the wrong direction will mean that the circuit will not Function AT ALL. Once fitted, solder in place, and re-assemble the Instrument Cluster, and test. 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 EF Series Instrument Cluster EF Falcon Low and Mid Series Instrument Cluster Left Hand Side Instrument Cluster Connector Pin 1 Not Used Pin 2 Not Used Pin 3 Illumination + (Park Lamp Relay) +12V Brown Pin 4 Illumination - (Negative) PWM Ground Dark Blue / Red Pin 5 Brake Fail Ground Violet White Pin 6 Park Brake Ground Orange / Dark Green Pin 7 Not Used Black / Dark Green Pin 8 Fog Lamp Relay +12V Not Connected Pin 9 R.H. Blinker +12V Dark Green / Dark Blue Pin 10 Hi Beam Relay +12V Dark Green / Orange Pin 11 L.H. Blinker +12V Dark Green Pin 12 Cruise Control Activated Ground Violet / Light Blue Pin 13 Economy Mode (Trans) Ground Orange / White Pin 14 ABS Check Ground White / Light Blue Pin 15 Air Bag Ground Black / Yellow Pin 16 Rear Window Demister +12V Yellow / White Pin 17 Alternator Fail Ground Gray / Red Pin 18 Power Ground Ground Not Connected Pin 19 Not Used Pin 20 Not Used Right Hand Side Connector for Low and Mid Series Instrument Clusters Pin 1 Signal Ground Ground Black / Dark Green Pin 2 Fuel Sender Resistance Yellow / Dark Green Pin 3 Low Coolant Resistance Yellow / Red Pin 4 Speed Signal Input Pulsed White Pin 5 Speed Signal Out Data White Pin 6 Low Washer Fluid Ground Pink / Yellow Pin 7 Tacho Input Pulsed Pink / Dark Blue Pin 8 EEC Module Input Data Bluish Pin 9 Speed sender Supply +5V Red Pin 10 No Connection Pin 11 Ignition Power +12V Red / Dark Green Pin 12 No Connection Pin 13 No Connection Pin 14 Trip Computer Data Data Bluish Pin 15 Smartlock LED Ground Dark Blue / Light Green Pin 16 LCD Illumination (Negative) PWM White / Orange Black / White Pin 17 LCD Illumination (Positive) +12V Red / Dark Green Pin 18 Oil Pressure sender Ground to Ground White / Red Pin 19 Ground Ground Black Pin 20 Power +12V Yellow / Black High Series NF/DL Fairlane/LTD Instrument Cluster Left Hand Side Left Hand Side Connector - 16Pin Left Pin 1 Illumination + (Park Lamps Relay) +12V Brown Pin 2 Illumination + PWM Dark Blue / Red Pin 3 Brake Fail Warning Ground Yellow / White Pin 4 Park Brake Ground Orange / Dark Green Pin 5 No Connection Black / Dark Green Pin 6 Fog Lamp Relay +12V No Connection Pin 7 R.H. Indicator +12V Dark Green / Dark Blue Pin 8 Hi Beam Relay +12V Dark Green / Orange Pin 9 L.H> Indicator +12V Dark Green Pin 10 Cruise Control Activation Ground Yellow / Light Blue Pin 11 Economy (Trans) Ground Green / White Pin 12 ABS Check Ground White / Light Blue Pin 13 Air Bag Fault Ground Black / Yellow Pin 14 Rear Window Demister Ground Yellow / White Pin 15 Alternator Fail Ground Grey / Red Pin 16 No Connection High Series NF/DL Fairlane/LTD Instrument Cluster Left Hand Side Right part of the Left Hand Side Connector - 12Pin Right Pin 1 No Connection Pin 2 No Connection Pin 3 Door Switch Front Left (Passenger) Resistance White / Red Pin 4 Door Switch Front Right (Driver) Resistance White Pin 5 Door Switch Rear Left (Passenger Side) Resistance Black / Red Pin 6 Door Switch Rear Right (Drivers Side) Resistance Black / Green Pin 7 Fuel Flap Switch Resistance Dark Blue / Black Pin 8 Boot Lid Switch Ground White Pin 9 Check Suspension Ground Dark Green Pin 10 No Connection Pin 11 No Connection Pin 12 No Connection Right Hand Side Connector for High Series Instrument Clusters Pin 1 Signal Ground Ground Black / Dark Green Pin 2 Fuel Sender Resistance Yellow / Dark Green Pin 3 Low Coolant Resistance Yellow / Red Pin 4 Speed Signal Input Pulsed White Pin 5 Speed Signal Out Data White Pin 6 Low Washer Fluid Ground Pink / Yellow Pin 7 Tacho Input Pulsed Pink / Dark Blue Pin 8 EEC Module Input Data Bluish Pin 9 Speed sender Supply +5V Red Pin 10 No Connection Pin 11 Ignition Power +12V Red / Dark Green Pin 12 No Connection Pin 13 No Connection Pin 14 Trip Computer Data Data Bluish Pin 15 Smartlock LED Ground Dark Blue / Light Green Pin 16 LCD Illumination (Negative) PWM Black / White Pin 17 LCD Illumination (Positive) +12V Red / Dark Green Pin 18 Oil Pressure sender Ground to Ground White / Red Pin 19 Ground Ground Black Pin 20 Power +12V Yellow / Black Back 4 Pin Connector for High Series Instrument Clusters This Connector is used for the Brake and Park Lamps Bulb out warning. Pin 1 Brake Switch - Dark Green / Red Pin 2 Park Lamp Relay - Brown Pin 3 Brake Lamps - Brown Pin 4 Rear Park Lamps - Dark Green / Red
  26. SPArKy_Dave

    EL Cluster into XH?

    Made a quick copy/paste thread for u, @XF EDDIE Read here - EF-EL and XH clusters are all interchangable. Mid series clusters - Fairmont, Police and XR - (with volt/oil) just need an oil pressure sensor fitted. They're essentially plug and play. (note - low coolant light will likely be illuminated, unless you fit a coolant level sensor, or a jumper wire) The odometer dimming is only affected if u fit a Fairmont instrument cluster to a GLi. (Fairmont clusters, need a resistor soldered onto the cluster circuit board) XR and Police clusters, are not affected. Fairmont dash light dimming is done by the BEM (incl, smartlock, central locking, interior light time-out, wipers etc). Low series vehicles have a two stage dimming switch - dull, bright and interior light on - not controlled by the BEM. Fairmont dimmer lever, is a momentary action - hold the lever and the dash lights progressively dim down, then back to bright. Low series BEM's timeout the interior light like a switch, Mid series BEMs, fade the interior light to off. Odometer reading is stored in an EEPROM chip in the cluster This chip can be de-soldered and swapped between gauge clusters, to retain the original reading. The odometer backlight globe is a 1.2w grain-of-wheat globe, in a small plastic holder I'm not sure if the odometer backlight globe wattage differs between low and mid series clusters, but I tried a 2w globe once and it was noticeably over-lit, so changed it for a 1.2w.
  27. deankxf

    Adjusting handbrake at rear caliper

    if you can show a pic of what the book says, if its' got a picture? if your cable is too tight, the adjustment is under the car near the gearbox you loosen the nuts on the curved cable hook there.
  28. waderobertson

    Adjusting handbrake at rear caliper

    Caliper is fine, hand brake operates. I am chasing a skimming issue on right rear brake. Ive had the calipers off and reset pistons a couple of times. I was just wondering if the mechanism (assume it drives a worm gear) that the handbrake cable connects to on the rear of the caliper needs to be 'set' a particular way I.e. wound right in or right out when resetting the caliper piston and pumping the brakes back up? The manual says there should be a 5mm gap between the lever arm and the caliper housing but as soon as I connect the return spring it pulls the arm back against the stopper on the housing. Was wondering if this was akin to pulling the handbrake on and causing skimming.
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