How to fix intermittment dash lights on Astro Van.
I have had this problem -
"dash lights on & off, or out" - on my GMC Safari (same as an Astro) and on my '93 Astro Van. You'll have to pull the dash apart, which can be a little bit of a challenge. I just use my Haines manual and follow its instructions. There are screws to remove on the lower dash cover, and some on the upper dash cover. When the cover is off, the instrument light cluster comes out by removing several screws. Then the spedometer cable must be removed on some. This was a little tricky on the '87 GMC, but not a problem on the '93 Astro since
The Heater Control Module may also need to be removed. Be careful and geltle, as there are quite a few electrical and pneumatic connections here.
After the instrument light cluster is out,
LOOK FOR THE ELECTRICAL CONTACTS on the rear side. These are the contacts which supply power to the instrument cluster lights. Clean these contacts with very fine emery paper to remove any oxidation, and then clean with alcohol (rubbing alcohol OK). Then gently bend the contacts outward
slightly to increase their tension when the cluster is reinstalled.
NEXT, examine the electrical contacts in the dash itself (where the cluster contacts hit) and remove any oxidation, same as with the cluster's main electrical contacts.
REPLACE any dead bulbs, as there are several bulbs in these clusters. Bulbs can be tested with a
VOLT-OHM METER SET ON "OHMS" to determine if bad. The bulb holders rest on a thin flexible electrical circuit. Check the bulb contacts on this electrical circuit, and clean as necessary, but go real easy on the emery paper here - use alcohol mostly to clean. Clean the contacts on each bulb holder which contact the electrical circuit. Then, spring the bulb holder contacts out a little to make them tighter when reinstalled in the instrument cluster.
REINSTALL the cleaned instrument cluster in dash, and it should light up like new!
Note: If the speedometer needle is in the wrong position after your repair, drive down the street before you take the dash apart again. Mine "Fixed" itself on its own, much to my delight, as soon as I drove the van.
The reason the lights go "ON & OFF" is due to poor contact between these flexible power contacts on the rear of the instrument cluster and the main power connections in the car body inside the dash. The springs get weak after years of use bumping around on the roads, and just need a little additional tension to make good contact. Oxidation can also be a factor, and this is a great time to remove it. This explains why hitting the dash (or other impact!) can suddenly cause the lights to come back on without explanation.
This is not a five minute fix, but should not have to be repeated any time soon. Be patient and careful and you will have a long lasting repair!
Hope this information is helpful.
Astro Van Fan