Best Complete Diagnostic & Repair Videos for IPC PRND123 Issues on 1999-2002 Full Size GM Trucks

mrrsm

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We've all heard the expression "Stepper Motors and LEDs" whenever problems with Instrument Panel Clusters (IPC) raise their Ugly Heads. The same thing goes for the "PRND123" Displays, too as per problems with them "Dimming" or when they inexplicably TURN OFF.

But for those of us who own Full Size GM and GMC Trucks, circa 1999-2002... These expressions will NOT apply to the IPCs nested in our Dashboards. Here are the important distinctions:

The Basics of the 1999-2002 GM Full Size Truck IPCs:


(1) Instead of employing the "Stepper Motors" ...the 99-02 Full Size Pick-Up Trucks use Durable Air Core Dash Panel Gauges that will RARELY if ever Fail. This is because their Coils and Electro-Magnetic Innards are quite Wire Wound Copper and very robust. When they DO Misbehave with having either "Bouncing or Jittery Gauges Needles" this is because these devices are filled with Thick Oil that acts as a Shock Dampener that will occasionally diminish over time and require replenishment. This can be observed about half way through this related Video...again the entire session is worth watching:


The Gauge Repair becomes possible by using a hypodermic syringe filled with 90 Weight Gear Oil or some other Oil with similarly thick viscosity. The Oil gets injected inside of the Metal Casements over the 'Needle Axles' in order to displace the Air Bubble within. These Gauges are all very expensive to replace and can run as high as $100.00 a piece, so servicing whenever possible makes better sense.

(2) Unlike the Soldered-in LEDS on the other SUVs and Later Model GM Trucks, the 99-02 GM-GMC Trucks have Replaceable Dash Panel IPC Incandescent Bulbs that obviate the need to require a Technician to remove the Needles from the IPC front panels and then have to perform the R&R Soldering Jobs of some or all of the other style Gauges in order to change them. These Bulbs are easily accessible via their Twist Sockets after removing the light plastic back cover on these Early Model IPCs.

(3) The Logic Boards of the IPCs in the 99-02 GM Trucks are VERY well made and when they fail or show any performance issues; even the most difficult problems, like a Failed or Dimming Fluorescent PRNDL123 Panel. These issues be addressed once you have a better idea of HOW these Logic Boards and their components can be Accessed and Diagnosed using a decent DVOM or DMM and actually re-soldering some of the smaller component connections back onto the Boards. THIS Video arguably has the Very BEST Description of How To Do Just THAT:

 
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Chemman

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Magnificent information. Thank you for taking the time!!!!
 
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mrrsm

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Whenever I find things like this... I'm very glad to share what others have figured out for us...

About using the Automotive 75/90 Gear Oil as the "Inject-able Oil"... I found THIS "Stuff Of Choice" (and the means to deliver it into the Air Core Gauges) on Amazon via the identical, requisite Plastic Syringes as per the VOP (Video Original Poster) for very little $$$:

Super Lube 56504 Silicone Oil 5000 CST, Clear


https://www.amazon.com/s?k=Super+Lu...0+CST,+Clear&ref=nb_sb_noss&tag=elightbars-20

SUPERSILICONELUBE.jpg

20 Pack Plastic Syringe Luer Lock with Measurement, No Needle (20 ML)

https://www.amazon.com/s?k=20+Pack+...edle+(20+ML)&ref=nb_sb_noss&tag=elightbars-20

PLASTICSYRINGES.jpg
 
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mrrsm

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Our Good Friend "Dr. Shock" from his YouTube Channel has once again produced a very relevant Video covering MORE useful information about the "Virtually Indestructible" Air-Core IPC Gauge Motors that is well worth memorializing here. Just after viewing the Video... Check out what he posted as the 'By-Line" History about what he knows concerning these arcane, Copper Wire-Wound Air-Core Gauges:

Start Viewing around 10:30 into this Video...


This is an Excerpt from the Comments "Dr. Shock" added to his Video:

*** Please Note that I Disagree with Dr. Shock about NOT being able to use the Older "Yellow" versions of the Used Air-Core Gauges. They CAN be resurrected using the Liquid Silicone Injection as per the Information Posted at the Start of this Thread. He makes no mention of using this technique in the following Text. ***

This video goes over ONE possible cause for an erratic (crazy spinning needle) fuel gauge for old body style (OBS) GM trucks and vans of the 1990s and early 00s from Chevrolet, GMC, Holden, & Cadillac not working. In many cases the vibrating, twitching, bouncing, fluttering, and related unexpected jumpy behavior from the gauge has nothing to do with electrical grounds or the fuel tank sender, it is simply the effect of age on the aircore motor of the gauge itself.

The original internal dampening effect is lost, corrosion sets in and the air core motor gauge becomes unreliable and must be replaced. Note that I said "aircore motor", there are NO stepper motors in these years! The vehicle illustrated is an OBS (old body style) 1999 Chevrolet K1500 Surburban with the 6.5L diesel engine option, but the symptoms and repair procedure apply to all GM trucks and vans of the same general era - before the introduction of stepper motors beginning in model year 2003.

Though of course 1994 and earlier cluster disassembly is different. These motors were never sold by GM. NEW ones are in an off white plastic housing color, whereas the originals were typically a yellow color. Rather than the color, what you have to pay attention to is the calibration code letter in black on one of the housing ears as shown in the video.

But DO NOT BUY USED yellow original ones - the aircore motor calibration is from a fluid internally that degrades with use and age so every original has the dampening defect to some degree as well as corrosion - so you'll be risking a failed repair by buying used.

You can only fix the erratic behavior reliably by installing an (NOS) NEW air core motor OR a speedo shop re-manufactured one. Each GM gauge type uses a different aircore motor calibration, so again please take note of the letter codes below! Original calibration codes for these model years of Chevy / Cadillac / GMC / Holden:

F = Fuel gauge (94-99 OBS trucks only)
C = Fuel gauge (00-02 NBS trucks only)
P = Oil Pressure gauge (94-02)
V = Voltage gauge (94-02)
S = Speedometer and Tachometer (94-02)
S = Transmission Temperature gauge (00-02 NBS trucks only)
T = Engine Temperature gauge (94-02).

If your fuel gauge was very messed up you may be in the rare situation of not being able to perform the calibration procedure outlined in the video, in that situation you will have to get access to a new fuel tank sender, hook it up and use it to calibrate the empty, 1/2, and full positions accurately. You can similarly re-calibrate major differences in the other gauges by replicating the source input to them.

WHERE TO BUY THESE:

Only one seller left on eBay, USDashWorks, who is still selling the actual NOS units I have bought in the past. They have a $20 core charge now though and he's only got the "C", "P" "S", and "T" calibrations currently - https://ebay.to/2W7E2jf

Here's an eBay search affiliate link for all the Aircore Motors calibrations (skip over the yellow used ones unless they are rebuilt ones): https://ebay.to/2YjQOd5

Here's an Amazon affiliate link for just the C calibration: https://amzn.to/34OvXnD

And one for GM 25089350 / ACDelco part number PC195 (replacement instrument cluster bulb) at eBay: http://ebay.to/2uCn0Lm

Alternatively Dorman has a complete re-manufactured cluster for these trucks. Dorman 599-350 for auto & Dorman 599-460 for manual trans.

Here's an eBay affiliate search for these: https://ebay.to/2TzFQ1N

Here's some Electronics behind what's going on...

It is very important you first eliminate a faulty fuel sender, faulty grounds between your PCM and the fuel sender and your PCM & the instrument panel. Your in-tank fuel sender is sending an analog signal to the PCM.

The PCM is converting that to a digital square wave signal it sends to the instrument panel. The aircore motor for the fuel gauge is calibrated with a dampening fluid to smooth out the high and low points of this digital square wave signal. When that fluid degrades, the twitching begins. The gauge is otherwise accurate, until the aircore motor completely fails internally and then points off the gauge.
 
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