New vehicle to me, a 2004 Disco 2 was throwing codes on my code reader, but the service engine soon light wasn't illuminated. I presume someone may have broken off the LED bulb. Also not illuminating is the ABS, Traction Control and Hill Decent warning light.

A cluster out of a 2003 donor truck also does NOT have the service engine soon light illuminated at key position II, but does have the ABS, Traction Control and Hill Decent warning light illuminated.

A third cluster out of an unknown year, but the same part number, has all of the "proper" lights illuminated, including Service Engine Soon, ABS, Traction Control, Hill Decent Warning and all the others.

Questions:
- Should the ABS, TC and Hill Decent warning come on at key position 2?
- Can I swap out the good cluster for the one currently in my 2004 with no drivability issues? I want to test the cluster and drive the vehicle, but I also don't want to damage anything. I have read the "D" will blink, but will the truck operate normally?
- The good cluster has less miles than the bad one currently in my 2004 and am I correct that the mileage can be set to what is actually on the truck?

Pic #1 is current cluster in 2004
Pic #2 is from my 2003 donor
Pic #3 is from an unknown year, but same part number.

Pic #1, 2004 D2

Pic #2, 2003 D2

Same part number, unknown year.

 

It’s pretty easy to take the instrument cluster apart to see if the check engine light has been removed. I had the suspicion that’s what was happening in mine and sure enough, clipped right out! I just soldered in a new one- super easy and cheap if your comfortable with that.

 

Basically, there are 2 clusters. 99-02, and 03-04. Multiple part #'s for each but they all supersede to the most recent within the 2 ranges (99-02, 03-04). So -- You can interchange any 03-04 cluster into your car, without any compatibility issue. Go for the one that lights up everything. #3.

 

Answers added below.

Also, as nashvegas said, there are basically two instrument cluster designs. The typestyle for the numbers was updated as part of the facelift for the '03-'04 trucks. All three. clusters shown are '03-04.

Questions:
- Should the ABS, TC and Hill Decent warning come on at key position 2? Yes
- Can I swap out the good cluster for the one currently in my 2004 with no drivability issues? I want to test the cluster and drive the vehicle, but I also don't want to damage anything. I have read the "D" will blink, but will the truck operate normally? Yes, you can swap in the good cluster with no drivability issues. If the "D" blinks, the cluster can be synched to the BCU with a Nanocom, or the blinking feature can be turned off with a Hawkeye.
- The good cluster has less miles than the bad one currently in my 2004 and am I correct that the mileage can be set to what is actually on the truck? From what I have read here many times, the miles displayed in the odometer will default to the higher of the miles previously stored on the cluster or the miles stored in the BCU. So in the case of the clusters you pictured, the third cluster will go from displaying 128,xxx miles to displaying 137,xxx miles once installed in your '04.

 

Put in the cluster with all the working lights and the good news is there is no service engine soon light, but the 3 amigos are lit. I swapped in a different shuttle valve, but no change. Looks like the next thing to do is the shuttle valve mod.

 

Have you read the ABS codes? It may not be a shuttle valve switch fault. It could be a wheel speed sensor fault, which is often actually a problem with a wiring connector.

And by the way, I'm guessing you didn't swap in a different shuttle valve. You more likely swapped in a different shuttle valve switch assembly. And yes, kind of like a wheel speed sensor fault is more often caused by a failed connector, a shuttle valve switch fault is often (most often?) caused by the failed solder joint that Option B bypasses.

 

Correct, I swapped in a different shuttle valve switch assembly. I have two spares, so modifying one will be easy.

Reading the ABS codes takes more than just a common OBD2 scanner correct?

 

Yes, a basic OBDII code reader reads engine management codes only. There are at least a few code readers available in the $100+ range that read ABS codes too, and in many cases SRS and transmission codes also. I don't recall which ones those are, but there lots of threads here about that.

Where are you located? Perhaps someone nearby has an ABS-capable diagnostic tool.

Also, if I recall correctly some ABS codes persist until cleared. You'll need an ABS-capable tool to do that. On the other hand, the Option B bypass is inexpensive and not difficult, so if you don't have access to a proper code reader it's worth a shot, I suppose. But I really advise getting the codes read. Otherwise you are just shooting in the dark.

 

The shuttle valve switch mod worked. All lights on the cluster illuminate at key position 2, but they all go out when the truck is started, no more 3 Amigos. The only issue with the new cluster is the odometer blinks. It still counts off the miles but needs to be sync'd. The gear indicator P, R, N, D, etc work as they should.

I am in Western MA and work on Fort Devens if anyone has the ability to assist with sync'ing the cluster/miles.

 

I spoke too soon. Three Amigos came on this morning as I left for work.

What gauge wire needs to be used for the bypass? I used some pretty thin wire. Does it have to carry a lot of current?