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Hi,
Here is the link to Art's page:
http://cleanflametrap.com/speedo5/
I've done this operation twice on a 90 and 92 and it's pretty straightforward, just make sure you note exactly where the wires with the spade connectors attach-there are two such wires. Remember to unplug the negative battery cable before doing anything and go easy on the plastic trim pieces, they can sometimes be brittle. You'll need two Torx drivers one is T25 and the other is (I think) T30.
Also when you insert the gear and close the small gear housing, take a small pick and gently (through the hole in gear housing) turn the gear little by little. If there is resistance, open housing and re-seat the gear, otherwise make a full rotation or two to verify the gears are turning freely-your mileage and tachometer should register change on the front.
Someone might chime in with more info but I know that normally that gear is a 25 tooth gear, there is however a 26 tooth gear but I am not sure what model year(s) of the 240 the 26 tooth gear would have been used. You might want to verify before purchasing a gear.
There is a small gear pod that could be damaged but it's doubtful as I don't think that is a common failure piece. More than likely your problem is the common gear failure. However, you won't know until you remove gear and examine it-if it's missing a tooth or more or if it's bendable/squishy-it needs replaced.
I would purchase a gear either from odometergears.com or FCP (they sell the odometergears-made now) as they are known to be reliable and well-made.
Take it slow, easy and you can do it.
Travis
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