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I have a good one that I could use some expertise on. Headlights off = tach works perfect. Headlights on = tach sticks at various RPMs. If I punch it to pass someone, it will stick somewhere on the dash and not change until I hit a bump. Never noticed it until I changed the guage face to white. I thought it might be getting hung up on the guage face itself but it doesnt do it with the lights off. WTF? Any input?
With my limited knowledge.. but run into this pretty regularly.. it sounds to me there is a grounding issue somewhere. Or a loose connection somewhere.
One thing thats happened to me is I installed some speakers and had a wire loose and touching something.. and every time I would hit a bump or close a door radio would go out. Hit a bump and it would go back to normal.
So.. it maybe worth checking you connections on the cluster.
Most times when an electrical component like an IPC goes nuts only with the headlights on (or other high load), there is a ground issue.
Tach and speedo sticking is common but usually on the 03+. The fix for those is a new IPC....but I don't think that's what you have.
Yeah, I would think the needle is sticking on the new cluster cover at some point. Did you just replace the stick-on gauge cover? If so, you have have pushed the Tach needle on too much. GO back and take the gauge cover off and reset the Tach needle.