I have read a number of threads relating to the removal of the instrument cluster and there seems to be some overlap with removing the pod. Consequently, I am a little confused on the process from start to finish. So my question is - aside from removing the steering wheel and the cluster buttons - what else do you have to do to remove the instrument cluster? Do you have to remove the pod cover? TIA Andrew

 

ajmarton...fascia panels underneath; disconnect cruise control; loosen
clamp on back of stalk switch; remove (5 mm hex bit) bolt at each end
of pod (from underside); remove 2, 10 mm bolts from edge underneath; ease pod up and wiggle stalk switch off steering column, disconnecting
2 connectors on it as you do; disconnect 2, 14-pin connectors from bottom
of cluster, one at each end; unmount the button switch at bottom of pod;
continue lifting pod to clear column, and disconnect 3rd 14-pin connector
from back of cluster; as pod clears column, tilt so face is down.

On right end you'll see another 5 mm hex bit bolt to remove along with
aluminum bushing-spacer. Remember orientation of spacer. Undo bolt
and remove the cluster to the left and up. Careful of the foil circuit.

G' luck

 

This should help....

1. remove steering wheel
2. remove cluster ***** from front of pod, push wiring into pod

now, looking up from under the pod
3. remove the long plastic plate (2 screws), and remove the plastic cover over stalk unit (2 bolts, 1 screw)
4. unplug intensive washer button, headlight dimmer wheel, and wiper wheel. Be careful, these are small wires. (I actually unscrew the wheels from the pod)
5. remove bolts holding pod, one on each side. outboard is a 10 mm bolt, about halfway back from the front of pod, inboard is a 5 mm hex bolt next to the ignition.
6. reach back with fingers and pull down 2 connectors off the circuit board in back of guages. ( You will have to remove the third connector as you remove the pod)

now, back in driver seat
7. loosen/unscrew stalk unit, (screw is on the right hand side) so that unit can be pulled toward driver and rotated clockwise (doesnt take much)
8. pull pod toward driver slightly so that the ignition on the right side can clear it's hole. Then lift and pull pod out, remembering to reach back and remove the 3rd connector from circuit board. this connector is removed by pulling gently inboard (to the right, not down like the other 2) Top of pod can be tilted toward you as you remove it to make it easier.
9. pod and guages should come out as a unit, the left side of the guage cluster may want to fall slightly out of pod, so support it with your hand.

Remember to label the *****, where they go on the pod, label the wiring for each **** before pushing it into pod (there may even be an extra wire cluster on the left side...this was for the euro cars, so don't freak if you suddenly have 4 clusters and only remember 3)

Go slow, shouldn't present any problems. Install is in reverse, kind of tricky to plug in the connector in back and wiggle pod over the ignition. But if you get it right the pod will just gently fall into it's place.

Speak up if you need more help.

Good luck

Rich.....too many pod surgeries...

 

Errr, step #1 should read, "Disconnect the battery"!

 

I'm having a heck of a time removing the allen socket bolt underneath the instrument pod that runs up through the ignition switch casting/housing up into somewhere. I've now waffled out the hex, I have tried vise grips - prayed, anything I can think of but can't get that bolt head it to budge. I've read something about a phillips head and a lever post somehwere up above the casting on the Nichols tip page- but can't find anything remotely like that to unscrew. I assume its not a reverse thread and I've been turning the worng way....THe other three loosened easily in the normal direction. My next plan is to drill it out - but I'm not sure I want to try that hard - so ...

I'm about to just give up and forget about ever removing the pod and putting in the LED light set I bought - but before I throw in the towel - maybe someone out there has an idea that can emlighten this idiot on why I cannot loosen that one allen head socket bolt on the ignition switch side?

jtd
88 928 S4

 

It could be an issue of disimilar metals and the thread has siezed.
Drill the head off and replace the bolt.
Drastic but effective.
I have never seen this problem before.

 

I removed my instrument cluster the second (and third) time without removing the buttons. After removing the wheel and unbolting the pod, you can pull the pod forward over the steering wheel column and simply unplug the cluster and pull it gently out without removing anything else.

Just be careful of how you treat the wiring.

Sears makes a set of nut/bolt extractors that fit over stripped heads on the outside with a reverse spiral in them that work great. I just used on on the exhaust nuts on the 90, after I got frustrated and stripped it. It did the job with no trouble at all. They would work fine on the intstrument bolts, since they're easily accessible/visible.

Rod

 

you have to take the engine out.... If you havent noticed i am making this my fix it all solution.

 

JTD, I would do it " The Ron way ". It worked fine for me several times for changing bulb's. If it's only the 3 bulb's for backlight it can be done without even unbolting the pod. Just remove the long plastic thing underneath (2 philips screws). If everything fail's, pull the engine......