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You should find it pretty easy. It may seem intimidating at first, but there are only a few wires on the back of the cluster. See the picture for a general idea of where the wires (red/yellow, orange, black circle, black half-moon, clear speedo connector, optional red/grey tach wire and optional black connector plug for clock -red,green,black).
The circular black connector and half-moon connectors will probably be a little tough to remove, as it will be on there quite securely. The good news is that both of those connectors will only go on one way.
The odometer gear is a piece of cake. Remove those seven phillips-head screws on the back of the circuit board (arrowed in bright green). Then remove the circuit board from the housing. Next, remove the four speedometer screws in bright yellow. You should be able to pull the speedometer out (gently wiggle and pull if you have to).
You'll see two small flathead screws on the side of the speedo. You should be able to rest the speedo on a desk or table being supported it by the trip reset lever. Remove the two flathead screws and gently pull the smaller daughterboard from the side of the speedohead. Don't separate the board more than what you need to, as you'll see some thinner blue and black wires connected to the circuit board. Remove the disc-shaped gear and your broken tooth gear and replace the broken gear with the new one. I think you can manually test the gear by turning it by hand. The new teeth of the gear should fit through the clear plastic grooves rather nicely. Put the new gear on the round disc and put back on the shaft, resecure the two screws, and reverse the removal process. When you reinstall the speedohead, make sure that the metal pins from the cluster's circuit board are making full contact in the speedometer's openings -- if memory serves me correctly, the pins are towards the top of the unit.
If your temp gauge is acting up, check the temp compensation board... make sure it's seated properly. Be gently when you put everything back together, I've found out that a bump here and there may move the temp compensation board, causing your gauge to read high... then you have to repull the cluster and reseat it.
Let me know if you have any questions. I've got the whole process down to 13 minutes. lol.
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Regards,
Eric Staufer,
'89 244DL 119k
My 240 Page
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