Dashboard cluster not working after unsuccessful radio replacement

RPARKERHARRIS

MEMBER
2006 FORD E-SERIES VAN
V10
2WD
AUTOMATIC
125,000 MILES

Former U-Haul truck, based on E450 van.

Everything seemed to be fine except the radio display was screwed up, so I wanted to replace the radio. I pulled out the radio and cut the wires (15 of them) that were coming out of the hole. I also unplugged the antenna from the old radio. I tried to wire up the new radio and couldn't get it to turn on at all, tried reconnecting all the wires as they were, and the old radio didn't work either. Also, the dashboard gauges and dome light stopped working. I found only one blown fuse, the radio fuse. After replacing it, I tried wired both radios again and still neither works and no life from gages or dome light. I found voltage from some of the wires coming out of the radio hole using a multimeter, and the radio fuse blows again if I mash together the wires. But at no point is there any sign of life in the old radio, new radio, or gauges.

Any ideas?

3 Replies

JACOBANDNICKOLAS

MECHANIC
109,885 POSTS

Hi,

Since this went through a body company when new, please bear with me because wiring could have been modified or changed to accommodate the U-Haul box.

Now, I looked at the wiring schematic for the radio and found 15 wires, as you mentioned. Also, I found additional fuses that need to be checked.

Pics 1 and 2 are the radio schematic and pics 3 and 4 are the cluster and lighting schematics. I highlighted fuses that I need you to check. I also need to confirm which wire you are checking that blows the fuse each time it's replaced.

Fuses 14 and 38 in the central junction box are tied to illumination. They need to be checked. Additionally, fuse 22 (which I think is the one that keeps blowing) covers several different things. See pic 5 for a list. That fuse is in the central junction box (CJB) in the vehicle.

Additionally, there is a fuse 22 that is in the under-hood fuse box. It is tied into the radio as well even though its primary purpose is to power the accessory delay relay, so check that as well.

If fuse 22 in the CJB is blowing, let me know if it happens immediately or when you reconnect it to the radio. There has to be a short at some point.

Let me know what you find or if you have other questions.

Take care,

Joe

See pics below. Note: I had to cut each schematic page in half to make them readable for you. I did overlap them. Also, the last two pics show the fuses that need to be checked.

Images (Click to make bigger)

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Monday, December 27th, 2021 AT 5:36 PM

RPARKERHARRIS

MEMBER
2 POSTS

Hi Joe, I appreciate your quick response!

I've checked all the fuses you mentioned, and none are currently blown. The one for the radio that I found blown before was 27 under the dash. It's labeled just as "Radio." I suspect I blew it when I cut the wires from the old radio initially. I'm not sure which wires from the radio harness have to touch to blow it, but I think it may be black with green stripe and red with black stripe because with the key turned, I am seeing voltage (seems like up to 20V) on those wires with a multimeter.

The fuse does not blow when I wire either the new or old radio in, but there is still no sign of life on the radios or dash gauges - although interestingly, the gauges light up (the lighting up never stopped working). The instruments just don't function at all. I've been reading around, and many places are saying the dashboard circuit can go bad causing intermittent gauge issues. But this is not intermittent - they were fine until I cut the radio wires and now, they are totally nonfunctional.

I also found this question thread about what sounds like it might be the same issue: https://www.justanswer.com/ford/c1w42-2006-e450-instrument-cluster-radio-dome-light.html - They said the wire into the under-dash fuse box was cut and rerouted and there was an additional inline fuse. I wanted to check for this since mine is also a former U-Haul, but I can't figure out how to remove the fuse box. Can you help with that?

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Tuesday, December 28th, 2021 AT 7:54 AM

JACOBANDNICKOLAS

MECHANIC
109,885 POSTS

If the fuse is getting power (enough to blow) and you are getting voltage to the red wire with the black tracer, nothing is cut.

The red wire with a black tracer is vehicle power. When you turn the key on, it should have 12v (or battery power).

The black wire with a green tracer is ground. If those two touch, it will blow the fuse. When you cut them, the cutters likely caused the connection between them and caused the fuse to blow.

Now, if you have power, and it sounds like you do, and the radio won't turn on, then it's lacking ground. Try something for me. Plug the antenna wire into the radio and see if it turns on. Or make sure the black/green wire is connected to the radio ground. The red/black is power, so make sure it is properly attached to the radio and insulated to prevent a short. If you are unable to locate where the ground wire goes, attach it or hold it on the side (metal) of the radio housing to provide ground.

Let me know what you find. Also, if you can take a pic of the wiring so I can see it, it could help me.

Take care,

Joe

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Tuesday, December 28th, 2021 AT 4:13 PM