Electrical expedition

[dan]

I am having some electrical issues. Here is a quick summary of what I've recently done and what is now happening.
This is an exmod FFR from Alta. The wiring is fairly original. There are an assortment of wires in the back which deal with the trailer set up, and one or two of those may be in the wrong prong .
The truck was stripped down to just the bulkhead, dashboard , engine and frame , everything above was removed( along with all the lights etc). It has been reassembled and all the electricals reconnected. It was a bloody crusade. I sanded and cleaned every connection and applied a thin layer of vaseline.
I've tried everything I can think of and I'm stumped on a few problems.
When I turn the military light switch to the left(in any position as well as the position far right) the electrics go funny. My fuel level indicator goes past the full position( I have a 1/3 full tank) my hazards don't work, the glow plug light comes on, so does the mainbeam light. Everytime that the switch is turned to the left there is a audible click. This click seems to come from those square silverish multi pronged plugs. There are two in the dash behind the instrument cluster and there are some in the fusebox area.
This problem(s) just recently started and was happening intermittently but now has become the norm, while occaisionally evrythings back to normal. I can't figure it out.
The hazards also stop working when the ignition switch is turned to the on position. When they do work, the trailer light on the dash flicks with the hazards.
Am I looking at the option of some deeper issue . Possibly the starter solenoid, the 6 way light switch, or maybe the ignition switch? Some glob of melted wires somewhere!? Everything was working fine before I fixed it.
Another issue deals with the reverse lights. They were working, and then now just stay on. Can the switch be stuck on the on position?
Thanks.

[ANDYD]

Hi Dan,
I presume this is a 90 or 110? Is it 12v or 24v?

Sounds like there is a dead short somewhere in the circuit?
What I would do is disconnect all the items that are not working correctly and then start hooking them up one at a time to see what effect it has?

Sorry, very hard to diagnose over the internet!

good luck

[dan]

I have zeroed in a little more on the problem. I have the instrument cluster removed from the dash housing with all electricals connected. As per usual, the electrics go haywire when I turn the light switch on in any position. While moving the dash cluster about, I inadvertently made contact between metal on my instrument cluster and metal on the body. When this happened, the intrument cluster functioned as normal.

What I don't get is that I have a black wire on the instrument cluster connector. I have done continuity tests on that black wire and it is grounded. Why would the cluster work when it touches body metal(ground?). THanks.

PS Is it possible that an lt77 from an exmod 110, would not be fitted with a reverse switch? I have searched around but can't see a thing.

[Rovermachine]

It sounds like you have an electrical ground problem. When I rebuilt my truck and fitted all the electrics back I had something of the same issue. My head lights would only shine dim, the turn signals to not blink and would turn on at the same time as the headlights. By instrument panel lights would also illuminate in odd multiples. My problem was that the ground to the metal mud guard on the headlight/signals harness was not grounding properly. I can only think of five ground points for my Exmod 110. One for each of the headlight/signal harnesses, the battery, the trailer harness and the last being the fuel tank level indicator assembly.

My two cents