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Here is the entry from my maintainence log on speedometer needle replacement recalibration:
Service date: June 05, 2007
Facility: Home
Problem: PROBLEM: Replaced broken speedometer gauge needle.
Odometer: 220989
Cost: 40.00 (bought instrument cluster from 1985 240 Volvo sedan while in Corpus Christi, Tx.)
Diagnosis: Somehow....I don't know how, the speedo needle broke off while I was away overseas.
Work done: Carefully disassembled and photographed every item of donor cluster, and removed speedo needle. Carefully removed and photographed my instrument cluster and it's disassembly. Carefully marked all wires to the cluster, and disconnected the speedo cable. Attempted to remove speedo needle from my speedo with my fingers. No joy. I then used a fork....by slipping the neck of the speedo needle between the tines of the fork and prying it upward. No joy. I then took a pair of needle-nose pliers, firmly gripped the brass speedo neck, and gently but firmly pulled it with a twisting motion. Joy! It came off. I then cleaned the instrument cluster, and removed the speedo assembly from the cluster (easier to work on). I then pressed the donor speedo needle onto the speedo spindle. The speedo needle rests at about the 8-oclock position against the stop-pin. I placed the needle on and pressed it into place at approx the 7-oclock position (below the stop-pin - as recommended by volvo forum members who have done this before). After I pressed it into position, I then moved the needle up and carefully lifted the tip of the needle over the stop-pin (just below the "Zero"). I then reassembled the instrument cluster, re-connected all the proper wires and connectors, and inserted the cluster into the dash. once it was screwed down, I got under the dash, reached up into the mess of wires, and somehow managed to re-attach the speedo cable to the speedo socket. I replaced all the plastic guage covers, and tested the connections. All the dash and instrument lights work fine. It's ready for a test-drive.
Results: Took the car out for gas, and on the way, I noticed that the speedo reads approx 10 miles per hour slower than my actual speed. I checked the speed against my known RPMs at gear changes. Before the speedo needle change, I would consistently change into 4th gear at about 45MPH with RPMs at about 2500. With the new speedo needle, I change into 4th gear at the same RPMs, and same engine rev sound, but the gauge reads 35mph vice 45mph. It appears that I am going approx 10 MPH faster than the needle. Tomorrow, I will attach my GPS to my car, and compare the MPH and see just how far off my needle really is. Once I find out, I will remove the speedo needle, and press it on at the 6-oclock position and try again.
Attached the GPS to the car, and set off for the base. The GPS reads my actual speed as being 11 to 12 miles per hour slower than the speedo reading. I will need to remove the clear plastic window from the instrument cluster, pry off the speedo needle, and make sure I have the speedo needle pointing downward at the 6-oclock / 5:30-o-clock position. Once I press the speedo needle down at that position, I'll need to gently move the needle up toward the "zero" marking, and gently lift the tip of the speedo needle over the stop-pin and then release it. Replace the clear plastic cover on the instrument cluster, and then hook up the GPS for another test drive. If it works, great! If it doesn't, I may need to move the needle again.
Performed additional road test with speedo needle reset at the 6-oclock position. As before, gently pressed the needle down and gently moved the needle over the stop-peg. Put the GPS on the dash, and found that my speedo needle reads exactly what the GPS reads. Success!
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