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Solved. Before sending the cluster off, I decided to take one last look at it in hopes of identifying any bad solder joints. After squinting and staring at it until my eyes crossed, I went to Harbor Freight and picked up a magnification headset thing with an LED light so I could actually see. Then I found a joint that looked different than the others.
I've attached a pic under magnification that points out the joint.
It's one leg of a capacitor located in the middle/right side of the board. It had noticeably less solder than all the others, and under heavy magnification I could make out what appeared to be a crack all the way around. I used a really fine tip on my soldering iron to re-solder the joint.
I've now driven the truck several times over the last couple weeks and the problem is gone. This repair saved me a couple hundred bucks and at least a couple weeks of down time.
That's great you got it repaired yourself! I need to look into getting a magnifier like that. I had to look ridiculous doing my odometer repair with two pairs of reading glasses on so I could see what I was doing! LOL!
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