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No, you do not have to remove the speedo from the cluster. To access the small odometer gear, you will need to remove two screws that attach the speedo motor (?) to the speedo circuit board. Once the screws are removed, you can open up the "cover" and locate the small odometer gear. BE CAREFUL, DO NOT OPEN COVER TOO WIDE OR REMOVE IT TOO FAR AWAY FROM SPEEDO CIRCUIT BOARD. It is attached to the board by two wires. I'm not too well-versed in the technical terms. So as not to confuse you, go here:
http://www.hyperocity.com/volvo240/volvoodometer.htm
This is a very helful site!
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