Temp gauge/fuel gauge trouble shooting

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SlantedMark4

'74 Valiant 225 /6
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Hey guys
This thread should be a "how to" rather than a "what to do" thread which should help new people ot understand things. If my stuff is incorrect please feel free to make it clear! I am also pretty new to this stuff so many things might be incorrect.

Before you go troubleshooting make sure to check the fuses first! Also disconnect the battery if you're doing stuff with the wires.

I have the common problem that both, my temp gauge and fuel gauge dont work. We've found out in another thread that the first part to check is the IVR. If the IVR fails, both gauges won't work anymore. We've also found out that if one gauge breaks the other gauge won't work either (interrupted circuit). If the IVR is alright but the gauges still won't move, we have to check the gauges and/or the sender of each gauge.
To see if the gauge is alright, we can bench test it or ground the sender wire. Because I didn't want to remove the cluster once again, and to check the wiring itself aswell, I tried grounding the sender wires.


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Now in my car ('74 Valiant 225 Slant Six), both gauges seem not to work but I have a new upgraded circuit board with a built in IVR, so the problem is either the gauges, the senders or the wiring itself. Last time the car was running I have had the old circuit board installed which had a loose IVR connection which might have caused problems with the temp gauge. Even tho I've installed the new upgraded circuit board, the fuel gauge still won't move so I have tried to ground the wires. And how I mentioned before, please correct me if I did something wrong.

I then started with grounding them to see if the gauges move. I have made a wire with two clamps on it to connect it temporarly and then turn the ignition key to see if the gauge moves. With clamps the connection is better aswell than just wave around with some wire by hand.

I've grounded the temp sender wire to the limiter housing which is grounded to the body. Another way is to ground the temp sender wire to the engine ground which is the strap from the firewall to the engine.
Some A-Bodies have a ground strap on the back of the car, between the bumper and gas tank. Mine didn't have that strap (I have no idea why). I grounded the fuel sender to the tank straps underneath instead because it was the only bare metal i could find in that area which is somehow connected to the body.

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First I grounded the temp gauge, turned the ignition key and it moved slowly, but it moved. I then grounded the fuel gauge and it moved much quicker. Both gauges moved, so the gauges and the wiring should be fine. The fuel gauge still doesn't move when the connector is plugged on the sending unit, so I assume there's a problem with the sending unit itself.
To see if the temp gauge is working now, I'd have to go for a test drive and warm up the engine. If the temp gauge won't move either, there might be a problem on the temp sender aswell.

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That's the condition of the fuel sending unit. Quite crispy with the undercoat, mmmh. I have no idea what the previous owner smoked. The installed temp sender is a replacement, SMP TS17.

BTW, if you want to buy the upgraded circuit board aswell, here's the link: Instrument Cluster Circuit Board with Built in Limiter 1972 - 1976 Duster Valiant Dart A-Body (not sponsored).
Here are two videos where I found out how to ground and test the gauges -----
 
One thing I noticed right away in your picture is that you don't have the fuel sender ground strap in place. Without it, the sender can't operate.
It clips on to the metal fuel fitting coming out of the sender, bridges the section of rubber hose, and clips onto the fuel line on the other side, which provides the ground for the circuit.
It looks like this:
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. We've also found out that if one gauge breaks the other gauge won't work either (interrupted circuit
That is not accurate.

The two gauges are independent of each other except for the input voltage from the IVR and ground through the cir board

This video will help a lot.

 
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To ACTUALLY test these you need to do an "end to end" inspection and test.

Some preliminaries as these girls are old and can be corroded, loose, etc.

1...The harness connector pins on the pc board can be loose. Clean, flux with a rosin flux, and solder using proper electronic oriented lead/ tin solder
2...The finger/ contacts that the IVR plugs into (non ralley cluster) can be making poor contact with the PC board traces. Clean flux and solder bridges across. "Work" the IVR in/out several times to scrub the connections

3...The fake nuts on the gauge studs can lose good contact with the pc board. loose/ tighten several times to scrub the board clean. Consider using real nuts, ad maybe star washers

4...I would not screw with the IVR if it is a oem electro-mechanical one. Just buy an electronic replacement such as RTE

5...Find 1 or 2 common ground screws on the board/ cluster, add a grounding pigtail, and bolt that to the column support or dash frame. The cluster is OEM "poorly grounded" via the cluster assembly mounting nuts.

Now, rig the thing on the bench with a 12V battery, fully charged, or a 14V bench supply, not a charger, to the proper harness pin and ground.

You need either some test resistors, or a variable one that you can adjust to an ACCURATE ohmeter. An old but useable fuel sender will work. Substitute the proper resistances for the senders and note if they read correctly. The meter movements are the same Here are the test resistances:

This is a third party tester that mimicks the OEM one shown in the shop manual. It is a 3 position switch that selects the 3 test resistances, for low, mid range, and "hot" or "full"

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There used to be a GREAT thread on repairing these, but the photos were posted via photophucket, and YOU ALL REMEMBER the big mess that company caused when they got greedy.

Also always remember that "new" does not mean "good" (functional.) Even though you spent good money on a new pc board, limiter, or whatever, it is always possible that something is DEFECTIVE

Also, you are assuming the wiring is "good." Maybe not. Maybe there fuel sender wire has a poor connection in the kick panel connector, or as others have mentioned, the SENDER IS NOT ACTUALLY grounding.

Same thing with temp. It goes through the bulkhead connector, and the little ---how old is it again?--push on connector at the sender may be loose, corroded, dirty

"End to end" test. This MEANS "end to end."

If you are working on a two-way radio, for example, this means from the mic to the cable to the connector to the radio to the coax to the antenna. And from the power supply and cable, fuses to the radiol
 
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