240 General: How-To Volvo 240 Odometer Cog Replacement

[Big 240]

So today I got round to repairing the broken odometer on my 1989 240 GL. I know it's not a major issue on these cars, but I like to have things working as they should.

Firstly you need to remove the instrument binnacle, 4 screws and it's out. Remove the dash clock surround and the panel below that (they just push clip on/off) and the same with the headlight panel to the right of the dash (pull the headlight knob and the dash dimmer knob off) then prise the panel out

You will see two screws on each side, remove these and you can then wiggle the instrument binnacle out. There are a few connectors/terminals round the back that need disconnected. Carefully unplug these.

Now you are left with this:


Remove these seven screws:


Separate the two parts:


Remove these four screws and seperate the Speedo from the panel:


Remove these two screws to gain access to the odometer cogs:


Be careful when lifting away, it will need to stay hinged due to the wires, watch carefully for the cogs dropping off, supporting them helps:


Now you will see the cogs. you can see the small white one with the missing teeth, this is what I needed to replace, I've also circled where I found some of the broken teeth off the cog, so check yours:






That's it, now remove the broken cog and replace with the new one. You can lubricate with about of vaseline etc at this stage. When refitting it to the speedo, take care to ensure the cogs stay in place, and it fits nice and tight. No need to force it as the cogs teeth should mesh nicely:


And that's it really, just refit the speedo back into the binnacle, make sure the three pins connect in their respective guides:


I took the opportunity to clean the years of dust and dead flies out of the display area of the panel, the coloured bulb panels came away easily:



Refit into the dashboard, job done.

[Big 240]

Bought the parts here:https://www.onbuy.com/gb/odometer-ge...iABEgJFL_D_BwE

[Moomoo]

Aye, me too!👍

Great thread BTW.🧐

[Big 240]

Originally Posted by Moomoo

Aye, me too!👍

Great thread BTW.🧐

Cheers man, yeah I bought the cog from them after you had posted it, satisfying job to do.

[Othen]

This was a really good 'how to' guide; well done.

Alan

[Big 240]

Originally Posted by Othen

This was a really good 'how to' guide; well done.

Alan

Cheers Alan, the Articles/How-To section on here is just full of blank Photobucket thumbnails haha so I thought I would start doing my own