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Cluster Service and Repair - Brake System Warning permanently on

5 August 2014
Around march, a cluster from France arrived with the famous "permanent brake system warning" and about 70.000 km of roads travelled. Using the tester, the issue was confirmed quickly. RPM values were ~500 too high, speed about 10 km/h too much. Illumination bulbs were darkened but all working - quite normal values for a cluster of this age and mileage.

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RPM being ~500 off

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darkened bulbs

Corrosion near the ceramic hybrid chip (HIC) marked the reason for the permanent brake system warning.

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.. at the middle of the special IC

One of the larger voltage stabilization capacitors showed heat damage - visible as heat shrink that starts creeping away:

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All components were removed, cleaned thoroughly and re-installed with a complete set of new capacitors, carefully selected to match their original purpose (like low electric leakage and bi-polar).

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cleaned and tinned

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all in place

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replaced where appropriate

Followed by checks and calibration, confirming the brake system error was fixed, all indicators were working and the illumination was even across the whole cluster.

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night view


PS: The animated GIF from the speed dial somehow isn't working ..
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