GuageClusterFixing

From John Clarke Mills Project Wiki

The gauge cluster seems to be in pretty good shape. All the bulbs work, the speedometer works fine; however the odometer does not work.

Here is the advice that I got from Curtis A. Ingraham:

0. Remove instrument cluster from dash. 1. While speedo is still in cluster, loosen big nut on back of speedo. 2. Remove speedo from cluster. Handle carefully. Resist temptation

  and do not touch needle or face.

3. Remove big nut and washer from back of speedo. 4. Remove speedo from back plate. 5. Notice that:

 a. Speedo cable input on rear drives speedo;
 b. Shaft from speedo to odo drives odo number wheel shaft;
 c. Odo shaft drives a big aluminum-colored gear at
    the end of the odo number wheel stack;
 d. Odo is not turning because that big gear is slipping on
    the number wheel shaft;
 e. Number wheel shaft is held in position by friction with big gear.

6. Gently slide the number wheel shaft back and forth a very small

  amount to verify that it is loose.

7. Find a temporary replacement shaft of slightly smaller diameter,

  such as a nail or machine screw.

8. Replace number wheel shaft with temporary shaft as follows:

 a. Identify end of number wheel shaft withOUT the gear.
 b. Place end of temporary shaft against end of number wheel shaft.
 c. Slowly and carefully press temporary shaft in, forcing
    numberwheel shaft out.
 d. At this point, temporary shaft is in, numberwheel shaft is out,
    and numberwheels are still in place.

9. Locate position on numberwheel shaft where big aluminum-colored

  gear normally sits.  A polished band likely exists there.  Verify
  gear location by holding shaft against numberwheel frame.

10. With a center punch or cold chisel make a very light impression

   on shaft at gear location.  This distortion should be large
   enough to fit tightly in gear, but small enough to pass through
   numberwheels using finger pressure.

11. Try replacing numberwheel shaft in odo frame. Keep numberwheel

   shaft end against temporary shaft end.
 a. If numberwheel shaft won't go through odo frame or is tight in
    numberwheels, distortion is too large.  File slightly.
 b. If numberwheel shaft slides all the way in easily, distortion
    is too small.  Punch it again.
 c. When distortion is just right, shaft will stop sliding when
    distortion reaches gear, and will not go into gear with finger
    pressure.
 d. Use channel-lock pliers or a small vise to press shaft firmly
    into position in big gear.  Leave a very small gap between odo
    frame and small brass gear at other end of shaft.

12. Verify that numbers on numberwheels align correctly with

   rectangular hole in speedo face.

13. Remove shaft between speedo and odo by removing one screw.

   Turn numberwheel shaft with fingers and verify that wheels
   turn smoothly, and ten's digit advances when one's digit goes
   from 9 to 0.  Replace speedo-to-odo shaft.

14. Replace back plate, washer, and nut (finger tight) on back of

   speedo.

15. Clean speedo face with careful puffs of canned air. (If more

   cleaning is needed, use water and lens tissue.)

16. Replace speedo in cluster, engaging trip odo reset shaft. 17. Reassemble cluster. 18. Tighten big nut on back of speedo, noting alignment of speedo

   face.

19. Reinstall cluster in dash. 20. Test speedo and odo. 21. Reinstall underdash panels.

P.S. I previously advised fixing gear to shaft with super glue. That repair doesn't last nearly as long as the distortion method above.

Rear of the gauge cluster

Pushing out the odometer pin with a lollipop stick