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Old 06-09-2014, 02:18 AM
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Join Date: Aug 2013
Location: Los Angeles area
Posts: 590
Fuel gauge problem

I just rebuilt the instrument cluster on the 83 300TD US spec car. Rebuilt sounds more involved really, I replaced all the bulbs, painted the needles, and hopefully fixed the rheostat.

When it was apart I found the small plastic knob rattling around on the housing. I couldn't figure out where it went for the life of me. So, I torn apart the donor car's cluster, and saw the small plastic disc with a formed pin in the middle at one end of a spool of wire in the fuel gauge.

So, I went back to the other cluster, and sure enough there it was, but I couldn't get it to reattach...and it eventually caused the plastic rod that wire was spooled around to snap in the middle...

DANG, I straightened it back out, but for the life of me I couldn't figure out how to pull the gauges out, clearly the needles have to come off, but HOW?

Anyways, I'm not sure how well it will work if it will work at all...any suggestions?

1983 W123 300TD US spec Turbo engine, with Euro bumpers and manual climate control, and manual transmission.
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Old 06-09-2014, 09:38 AM
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Join Date: Sep 2004
Posts: 8,730
Originally Posted by crazy4diesel View Post
...clearly the needles have to come off, but HOW?
The needles are press fit onto the shafts. If you have a Dremel-type tool, use a cut-off wheel to cut a small notch in the blade of a small, flat screwdriver. Then use that to pry the needle off. Take great care not to bend the shaft excessively. Reinstalling the needle in the correct position is another challenge.
When cryptography is outlawed, bayl bhgynjf jvyy unir cevinpl.
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Old 06-09-2014, 10:37 AM
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Join Date: May 2005
Location: NYC
Posts: 8,221
Best way to remove the needle is with 2 spoons used as pry bars. Use thin cardboard to protect from marring the gauge face.

85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked
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