![]() While I was doing all this testing it dawned on me that my cluster wasn't grounded very well since it was just hanging there. I then grabbed the old one I had originally thought was bad, and it seemed to be working when hooked to the battery. I decided to remove the new regulator and check the output voltage by connecting it directly to the battery, I got 12v, so the new one is bad. I reconnected the gauge and the smoke was back, so now I was getting really confused. I fixed the main power wire splice issue, replaced the regulator, disconnected the new fuel gauge, and turned things on to find the smoking had stopped. The LED bulbs in the instrument cluster might be the cause of your problem. ![]() What I would do is pig tail the LED bulbs in the external taillight and park light lenses with a dab of epoxy and use the standard bulbs then you won't have any unforeseen issues. There are different flashers for LED bulbs because they use so little current, the Bi-Metal strip won't get hot and break the turn light circuit. The result is that the IVR will pass an average of 5V because the Bi-Metal strip will never stay connected to 12V long enough to pass 12V.Ī test light with the smallest wattage 12V bulb connected in series with a sensor wire from the fuel tank or temp gauge will allow the pulse of the IVR to be observed. ![]() When 12V is applied to the IVR the Bi-Metal strip heats and cools many times per second making and breaking the circuit. The IVR works on the same principal with a notable difference. Therefore The Flasher Relay Bi-Metal strip is heated at a different rate for which it was designed when a bulb is out. When a light bulb is out the Flasher Relay breaks faster or slower because part of the current load for which the Flasher Relay was designed for is absent. When it cools the Bi-Metal strip relaxes and re-connects the circuit. When voltage is applied to the Flasher Relay the Bi-Metal strip heats up and buckles breaking the circuit. The IVR and Flasher Relays work on the same principal but are designed for different voltage outputs. LED bulbs are polarity sensitive and don't use much current.
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