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How to replace those speedo gears in the XE Cluster


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#1 hendrixhc

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Posted 10 January 2010 - 07:38 PM

HI All

Thought i would post up some instructions on how to replace the speedo gear that deteriorates in the instrument cluster.

Tools required:

Gas soldering iron ( optional)
pliers
small flat blade
#2 phillips head
jewellers screw drivers
fine grade sand sheet
silicion spray
new gear which can be purchased on Ebay

Step 1) Remove the instrument cluster from the car.

Step 2) Remove the instrumnet cluster main PCB from the cluster by removing the six black phillips head screws.

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Step 3) Remove the speedo from the Pcb by removing the four screws, then remove the black cover on the speedo via the four screws

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Step 4)With the cover now removed you should be able to see the broken gear.

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Step 5) Carefully remove the pointer needle by pulling it away from the face of the speedo, then remove the two small flat blade screws to remove the face of the speedo. Take car not to bend the needle or to slip and scatch the gauge face.

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Step 6 ) Remove the four flat screws from the white gauge frame. This allows you to remove the gears and tumblers away from the motor drive.

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Step 7 ) Turn the gear set to the side and inspect the gears. you can now push the pin on the white geasr through to the center of the gauge and remove the gear. Remove the 2 circlips carefully and remove the black gear and the broken gear.

Step 8) Check the frame where the mounting pins for the gears are for cracks. I f they are cracked you can use a gas soldering iron with ca cutting blade to repair the cracks.

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Step 9) With some excess plastic, melt over the crack and the rear of the pin to provide some extra strength to the pin. Dont melt on the side of the gears cause, cause this could cause the geasr to stall and dont overheat and distaort the frame.

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Step 10) Inspect the mounting pin for any residual sticky gear ( from the old gear) and clean it off carefully with the sand sheet. Lightly lubricate the pins with silicon spray. Dont use oil or grease as these can go hard or react with the plastic gear and cause it to deteriorate.

Step 11) Get you new gear set ready and refit them in the correct positions

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Step 12) fit the circlips and turn the gears with your finger to ensure that the turn the tumblers correctly.

Step 13) Refit the tumbler frame to the main body of the speedo and check the worm drive gear on the speedo motor engages the new gear correctly.

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Step 14) Refit the face of the speedo and fit the needle at the 0km position. Move the needle to 60 - 80km position and release and ensure the needle rests at 0km. If it doesnt adjust the position of the needle and retry again.

Step 15) Refit the speedo to its cover, the speedo to the pcb, the pcb to the cluster and the cluster to your car. Road test the car to check everything works ok

Here is the iron i use to do plastic welding

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Good luck, i hope you find this usefull!

Hendrixhc.

Edited by hendrixhc, 10 January 2010 - 07:39 PM.
gear purchase

HendrixHC 82 XEGL Falcon 351: 66 Mk1 Cortina: 03 BAXr6: 06 SY Territory: 05 Hayabusa

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Project Thread : http://www.xfalcon.c...9834#post469834

#2 Big Matt

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Posted 11 January 2010 - 08:37 PM

Thats bloody awesome mate. Very useful:hy:
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#3 tbomb182

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Posted 11 January 2010 - 08:57 PM

nice mines stuffed in the xd so il give it a go !
XD 351
xp wagon 302 W

#4 hendrixhc

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Posted 11 January 2010 - 09:01 PM

Good luck tbomb182, its really easy and a bit of fun to!
HendrixHC 82 XEGL Falcon 351: 66 Mk1 Cortina: 03 BAXr6: 06 SY Territory: 05 Hayabusa

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#5 Guest_thunderbolt_*

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Posted 05 February 2011 - 12:28 AM

this is a good thread i will have a go at fixing mine.

#6 c4colinoz

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Posted 01 May 2011 - 12:38 PM

Do the xf gauges suffer the same problem? Just replaced the cluster on mine and the odometer still doesn't count up

#7 ILIED

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Posted 01 May 2011 - 12:47 PM

That was very informative and will help a lot of members.

+1 rep points for you mate.

#8 Guest_thunderbolt_*

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Posted 01 May 2011 - 04:56 PM

Do the xf gauges suffer the same problem? Just replaced the cluster on mine and the odometer still doesn't count up


yep
just done mine a couple of months ago
the XF one is easier to fix than the XD-XE one

#9 SZKsa347

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Posted 17 January 2012 - 05:26 AM

great photos and easy to follow steps

my odometer in my ZK (XE dash) has stopped, but the speedo still works.

I had a quick look on ebay and found a set for a XF dash, are they the same?
SZKsa347

#10 IGOWLD

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Posted 27 July 2012 - 06:44 PM

just wanted to say i used parts of this guide for the things i was unsure about and it helped me out, so Thanks and my odo is back up and running.
"BUILT FORD TUFF"

#11 MikGan

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Posted 27 July 2012 - 06:47 PM

Thats a great doc, any chance you could expand on step 1, remove cluster from car?

#12 IGOWLD

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Posted 28 July 2012 - 07:34 AM

Thats a great doc, any chance you could expand on step 1, remove cluster from car?


Removing the cluster from dash

There are 4 screws two at the top and two at the bottom unscrew them.
There are also two screws that hold the light switch mechanisium in unscrew them two as well.
Then i just unpluged the plug from the left side and pulled the cover over the steering wheel but still left the light plug attached.
then there is only two screws holding the dash in. Unscrew them and out she comes.

Hope this helped you out.
"BUILT FORD TUFF"

#13 XES

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Posted 04 June 2013 - 08:51 PM

Did this fix last weekend and it worked great James! Thanks for the guide mate.

#14 hendrixhc

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Posted 04 June 2013 - 09:02 PM

Did this fix last weekend and it worked great James! Thanks for the guide mate.

 

No worries Pete! Pleasure to help out!


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HendrixHC 82 XEGL Falcon 351: 66 Mk1 Cortina: 03 BAXr6: 06 SY Territory: 05 Hayabusa

Posted Image

Project Thread : http://www.xfalcon.c...9834#post469834

#15 gergatronic

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Posted 04 June 2013 - 09:41 PM

Was gonna do a write up but then I saw this... Well done! Did mine a few weeks ago and I'd say the hardest bit was getting the old perished gear off the shaft without breaking the housing that the pin mounts in, which was already cracked. Super glue fixed that. The old gear must have been made from some funny plastic like neoprene cause it's rubbery and crumbly. The new one just looks like high density nylon. I got it online from a place called "Parts Lunacy" for $17 or so. Good, prompt service.

On assembly, I lubed all the gears with a bit of silicone spray, should do for quite a long time. So far, so good.
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- Gerg

#16 hendrixhc

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Posted 04 June 2013 - 09:46 PM

Those gears went the same way a lot used to go in old canon photocopiers.

 

The manufacturers were always changing the material types cause of failures like this. One thing you needed to be careful with was using any lubricants on the gears cause it could cause them to "break down" and fail.

 

Silicon spray seems to work alright tho! Plus it smells great!  :hy:


HendrixHC 82 XEGL Falcon 351: 66 Mk1 Cortina: 03 BAXr6: 06 SY Territory: 05 Hayabusa

Posted Image

Project Thread : http://www.xfalcon.c...9834#post469834

#17 XES

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Posted 04 June 2013 - 09:47 PM

Thats the place I got mine Gerg.  And my old gear was exactly the same.



#18 n00bus m@x1mus

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Posted 04 June 2013 - 09:52 PM

I picked mine up from a wrecker for 10 bucks and did exactly the same thing... was a different colour but think it was black.  And i just used some graphite grease i think i had left over from another job.


Sig01.jpg


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#19 XES

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Posted 04 June 2013 - 09:58 PM

I used teflon grease. It was what I had and better than normal grease. Teflon grease is the shiznit!!




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