I need to take the instrument cluster(K9800) out of my 1988 240 wagon so I can replace the odometer gear. I have taken out several instrument clusters out of wrecked cars before but I have always managed to break several trim pieces during the operation. Does anyone have any pointers on how to take one of these out and be totally successful?

Thanks,
Carl

Excellent! Thanks for the advice and the pictures too. As soon as my gear gets here, I'll be clocking the miles again.

You have to remove the trim on either side of the cluster. The two square plastic blanks to the right will just pop out. Use a screw driver or a car key to pry them gently. Then pull off the headlight and dimmer knobs (no need to twist, they pull straight off). Pry out the plastic trim to the left of the cluster and disconnect the rear fog light switch wiring. Remove 2 screws per side on the cluster. Then remove the two screws holding down the plastic panel on top of the steering column. Now you can pull the cluster out far enough to disconnect the wires (write down where they go). There's also a little metal plate on the left side, which you should pull off before sliding the cluster forward. It's really quite simple.
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Volvo 240 Links | Volvo 240 Racing Gallery

This is a very good description and is correct for the '81 and later cluster but does not apply to the early style which is what we are dealing with here.


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'80 DL 2 door, '89 DL Wagon

I pull the knobs off of the light controls to the left of the cluster and then pop that cover off with a flathead screw driver (or more often, the ignition key) and repeat with the 2 square pieces to the right of the cluster. Granted I have a stripped down dl model with no extra gauges so if you have gauges there that last part might be different, I don't know. Removing the plastic exposes the 4 moutning screws and then the cluster can be moved enough to get a hand behind it and unplug everything. MAke sure you note where the spade lugged wires go and that you remove the retainer thingy on the plug for the speedo without breaking it like I did. Not a major issue if you do, mine still works and has never fallen off. If you have the other gauges I'm sure someone will post their versionof the how to.
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Portland, OR 1987 240 dl wagon (not so rusty anymore) 'rustbucket'

The other two posts are dead on. Just be certain to jot down where the wires connect to on the back of the circuit board. Here are some pictures for once you get your cluster out:

http://www.homestead.com/volvo2/88speedo.html

Hope this helps..
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Regards,
Eric Staufer,
'89 244DL 118k
My 240 Page

Just found this thread! (going to be super helpful this weekend)

But the Link is broken- is there another place I can go to see the Pic's of "dashboard Dis assembly" for my instrument cluster repair/ replacement endeavor?

thanks!
Justin
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1979 245 DL

Look at TP11410 on k-jet.org http://www.k-jet.org/documents/greenbooks/200-series/

Page 44
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Art Benstein near Baltimore

Raising teenagers is like nailing Jell-O to a tree.

TP11402.2, page 55.

Boy, Art, those instructions are minimal. Adequate, I guess but they seem to predate the Lambda-Sond reminder. That should be self explanatory, though.

I surprised you haven't documented this procedure.

And now, it's time to go to work.


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'80 DL 2 door, '89 DL Wagon

Yes, those you found are much better, and in my recollection of doing the removal, adequate. The method of relaxing the snap clips at the top is stated in better words than I could have written.

Then I discover I have that manual too.

"I surprised you haven't documented this procedure. "

I was thinking the same thing, or rather that I have, but lost it. Well organized I am not, my memory sucks, but I do recall posting this picture very recently, which helps by showing the spring clips holding the IP in the dash.

Location of Illumination bulbs for instrument cluster on '79 Volvo 240 200 1979

"And now, it's time to go to work. "

Amen
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Art Benstein near Baltimore

GREAT TRUTHS THAT ADULTS HAVE LEARNED:
Middle age is when you choose your cereal for the fiber, not the toy.

Better words or not, the dang things always make a break for it when I try to remove the old style cluster. Found one of them hiding behind the firewall carpeting once. I must be doing something wrong. At least I was able to retrieve it.

I am home from work now and today was a grueling experience.

Great pics, as usual, Art.


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'80 DL 2 door, '89 DL Wagon

This is for the '79?

I'm pretty sure that link was for the later cluster.

You'll be glad to know you don't have to remove the whole dashboard.

I would explain it but I'm rather tired.

Someone will help you with this. Or I will if no one has by the next time I check.

It's not too difficult.


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'80 DL 2 door, '89 DL Wagon