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I had the same problem and performed quite a bit of troubleshooting as well. Then one night the cluster illuminated. Sometimes it doesn't still. Very irritating. So my interim fix is a 12 volt LED strip which I can plug into the accessory outlet and place it between the cluster bezel and cluster.
I contacted the manufacturer of the cluster and asked for assistance with repair/troubleshooting and they were not much help in the end. i even offered to send the cluster to their location and let them know that the problem is fairly common.
They give a Schitt because Ford paid them already for those parts and they do not normally deal with the end user.
Good luck
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2003 Cobra Vert Anniversary model
Mods: Kenne Bell 2.2, Billetflow idlers (4), Accufab single blade throttle body, K&N GenII CAI, Fore fuel hat with dual GT40 pumps, Dual FPDMs, wiring upgrade, Siemens DEKA 60# injectors, Racer Walsh HUGE heat exchanger, Magnaflow catback with Magnapacks, Bruce's full IRS Delrin Bushing upgrade kit, Billetflow differential brace, Bilstein sport coilovers 400#front and 600#rear spring rates, Maximum Full length subframe connectors, Maximum caster/camber plates, Maximum front control arms, Maximum solid steering shaft, Maximum front tie rod ends/bumpsteer kit, Maximum aluminum steering rack bushings, Maximum IRS adjustable tie rods, Maximum adjustable swaybar end links, 18" FR500 wheels, Cobra R Brembo brakes with 2 piece rotors, Fidanza aluminum flywheel and head cooling mod awaiting install when clutch arrives, Steeda firewall clutch adjuster and billet quadrant, SCT X Cal2, tuned in Germany by TONY from HP-Performance (Orange Park, Florida) 607 RWHP.
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