Chrysler Repair: 94 T & C weird electrical problem, copper run, washer pumps


Question
"The 4 bar graph gauges in this van (with 3.8L, 140K mi., AWD) have not worked right in about a year.  Though probably not related, since months before that, the radio and/or it's clock display has been intermittent. A few times the radio will suddenly come back on with just static and I can't turn it off w/o cycling ign. switch. The radio may be out from an hour to a week or work fine for similar periods. RR speaker is also beginning to fail.



GAUGE PROBLEM DETAIL - The oil psi, fuel level, eng. temp & batt. volt gauges in the EI-Cluster (main problem), "freeze" in same position when key is in ON position (example 1/8th tank of gas).  After < 1 min. (with or w/o eng. running), all but batt. volts falls to zero and the 6 digit odometer is replaced by a blinking dot just above 3rd and 4th digit. The odometer is restored and the gauges go back to their "frozen" values if one of 4 devices are used (head lights, wipers, open door or slide dimmer switch to full ON position) .  Never have had problems with starting - running - stalling (knock on wood).

WHAT I'VE DONE - Ran on board "CHEC" of EIC several times got code 920 then 999 once but only 999 all other times.  Nothing before code 55 on ign. sw. cycle test. No change with radio removed. Per library Mitchell repair manual, I tried to locate common ground in either kick panel or center rear of I/P, but failed. Most of dash is apart with Left&Right PODs hanging from connectors. Can't figure out how to remove pass. side with glove box and air bag.  Sleeve # 12 (green wire) on BCM blue plug has signs of overheating (plastic bulged on side and end of blue plug and dark around pin on BCM).  Thought I had bad spot on ckt. bd. path but copper run looks good once varnish removed.  This makes sense, since rear wiper failed sometime in past month (but washer pumps).  BCM has 119 ohms on serial bus +/- (pin 7&20). Have 12.65 vdc on pink-8, 12.34 on Dk.Blu/Yel-6 and Blk/Lt.Grn-19 has < 1 ohm to ground. Even ran GND. jumper to air bag module bolt head.  Have removed/inspected TCM and ECM and cleaned batt. posts & double + posts on PDC.  Removed windshield wash tank and rem./inpect large firewall harness connector.  Nothing obvious on EIC or BCM ckt. bds.  Have visualed many fuses but not with ohmmeter. About to hit library for more Mitchell help with ECM.  Got new fuel pump last May, but maybe eng. temp. or oil psi. sending units are bad??  Thanks in advance.


Answer
Hi John,
This is a very lengthy history and will require some time for me to review and get back to you. Please use the 'thank and rate' tab to give me your email address where I can reach you in a day or two at most.
If there are several different problems we may need to deal with them one at a time with a separate q and a for each.
Roland