This is my post from a year ago. It's now 3 years since I converted to
an electronic voltage regulator and still working perfectly. The only difference you'll notice is the needle movement is slower than the stock setup on engine startup but once they normalized the needles are rock solid, no more back and forth quivering. In retrospect, I think the root cause of my gauge problems may have been caused by high ambient temperatures in area of gauge cluster. (This fix is only applicable to '86 models & earlier because Ford changed to magnetic gauges beginning in '87.) Anyway, this what I posted last year:
++++++++++++++++++++++++++++++++++++++++++++++++++++ I had the same problem 2 years ago on my '86GT and it drove me nuts. Replacing the voltage regulator, checking all the chassis grounds and even connected a ground wire directly to the regulator failed to corrected the problem for me.
What I did was convert the stock voltage regulator to an electronic version for less than $5 in parts. All I used was:
7805 fixed voltage regulator
47uF electrolytic capacitor
10uF electrolytic capacitor
6" of wire (about 24ga)
I pried open the stock regulator, cut-off the contact springs. Use the remaining spring stubs to solder the input & output circuits to. I used a pop rivet to mount the regulator to the bottom of the metal case. Use electrical tape line the internal sides of the case prevent inadvertent grounding of the bare component leads. Although it was a little tight, I was able to fit all the components inside the case with a little planning. In retrospect, I may have substituted the capacitors with tantiliums for space considerations only because these are more costly. After that, just re-assembly everything back together.
You'll probably read elsewhere about the need to mount a 7805 regulator on a heat sink and also question the ability of it to drive
3 gauges (oil, temp, fuel) simultaneously. All I can say is that I've had absolutely no gauge function issues since the conversion and I'd recommend it to anyone.
With the instrument cluster already out of the car, I'd suggest you that you check the "High' and "Low" calibration points with 10 ohm &
73 ohm resistors. If the needle is out of calibration, there 2 small serrated adjustment wheels on the back of each gauge. I'd recommend this procedure only for the oil & temp gauges. I didn't have much success with the fuel gauge calibration and I had to 'tweak' the "high" calibration a couple of times after the fact because with a full tank of fuel, it registered only 7/8 full.
Enough of my ramblings.
Good luck.
C.J.