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  #1  
Old 09-12-2003, 12:01 AM
Mr Goodfahrt's Avatar
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Question My Successful Cluster Fix Saga - TIPS and NEWBIE MISTAKES

1982 300D Turbo White 200K+(?)

Thanks to this board for great info and links! With your help I've fixed my cluster lighting, tachometer, odometer and trip milage in addition to painting the needles and doing a general cleaning.
Here is my story and some of the things I learned.

I acquired my beauty from a recently based on a recomendation from a freind. I haven't worked on a car since my college days except for an occasional oil change or filter replacement. My freinc told me he wouldn't sell me the car unless I would learn to work on it myself, thus my finding this board.

My first project was to replace the air filter housing (successful) and flushed with success, overconfidence and the info from this board I endeavored to attack the nonworking instruments and poor lighting in the cluster.

My first attempts at removing the cluster from the front with a highly modified garment support device (hanger) was a failure. I then took a deep breath and attacked the problem by removing the underdash panels and pushing the cluster out from behind (easy). My next challenge was fitting my hands behind to undo the various wires and cables. Since this was my first experience behind the dash I had no idea what was "pullable" and what was bolted, screwed or fastened. With some trepidation I carefully removed what would pull away with out any tools and was left with only the oil pressure cable, which was undone with a 10mm open end wrench. FREE AT LAST!

When I first pulled the cluster, there were things rattling around inside... very scary. Knowing I would have to remove everything anyway, I proceeded to remove the screws and take out the instruments left to right as described in the MBZ.org site on rebuilding your cluster.

After removing the instruments several bits and peices fell out of the housing. These were a small mystery spring, two screws, a small piece of translucent red colored plastic and several bits of black plastic. I eventually identified where all of these came from!

The first thing I noticed was that the odometer and trip counter numbers appeared dirty from an oily coating. I later determined where this came from. If you don't tighten the oil pressure cable sufficiently it will spray oil! (You guessed it... I found out the hard way).

Moving along... I cleaned the numbers with a Q tip and alcohol, and proceeded to attack the odometer repair. I didn't have a drill bit or coat hanger the right size to push out the shaft as suggested from the MBZ.org article, but I did notice that the shaft that supported the trip mileage was the same so I removed that and used it to push the main shaft out. This later recquired some reasembly of that part, and this is where I determined that the mystery spring had come from. It provided extra tension on the trip mileage in addition to the spring in the pushbutton/reostat.

I completed the shaft ruffing-up/locktite technique repair, and proceeded paint the pointers with testers flourescent orange which I found at my local hoppy shop. I covered the dial faces with a cirlcle of paper with a slit in it. This dried in about 20 minutes and looks great!

I gave the silver dial centers a quick breath-and-rub, but one came off! Apparently they are flimsily held on by some brittle brown stuff. I reattached it with a mild glue-stick adhesive, and proceeded to reasemble after carefully cleaning the plastic with a soft cloth (not paper).

I also cleaned the inserts that have the symbols on them... they come out from the edges of the cluster. Don't rub on the white symbols though... they can smear.

There also is a "mystery" grey insert that removes from the bottom center of the cluster but has no symbols on it. I assume it is for different options or models other than my 300D 123. Anybody know?

I also replaced all of the bulbs, and carefully cleaned the translucent light conductors which reflect the light from the back of the cluster forward to the dial faces.

The tiny bit of colored pastic came from the hole where the reserve light shines through. This had been missing.

Assembly was simple after understanding the hooking of the trip mileage arm properly. Some of the screws had been stripped, thus accounting for the small bits of black plastic rattling around.

Reasembly was much easier... I knew my way around by then, but as alluded to earlier, I didn't tighten the oil pressure line properly and found dripping oil on my lap 10 minutes after taking my wife out for a ride to "show off" the bright new working cluster (embarrasing).... "Don't worry honey.... it's only a little oil leak! By the way, I hadn't read anywhere that actual OIL came through that line!!! Don't let this happen to you.

I hope others will benefit from this narrative. I would never have attempted this without the great help and info on this board, but now I wouldn't hesitate to encourage any other Newbies to proceed and "Go-For-It".

I didn't take any pictures this time, but I will in the future if helpful to others. Next time I will share my experience doing my first coolent flush....

Thanks again everyone.... Mr Goodfahrt (newbie)

QUESTION: Would pictures of this project be of interest? I will illustrate it if someone will teach me how to upload photos to the board. I have a digital camera. Thanks....


Last edited by Mr Goodfahrt; 09-12-2003 at 11:19 PM.
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  #2  
Old 09-14-2003, 12:47 PM
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Here's a description of my cluster fix

Thought I'd move this up so it would be near the new posted topic on mileage.
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Mr Goodfahrt (pronounced FAIRT... means "good trip" in German)

1982 300D Turbo Pastel Gray (off-white) 200k+(?)
newbie but willing
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  #3  
Old 09-14-2003, 06:44 PM
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It's always a good idea to use a second wrench for a counter-hold while you tighten the oil gauge pressure line. Matter of fact, any time you loosen or connect a line to a fitting that has flats for a wrench you should counter-hold with a second wrench. It will prevent breaking a fitting at some point in your auto maintenance career.

Cheers,
Wes
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  #4  
Old 09-15-2003, 07:40 AM
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Mr. Goodfahrt,

Thanks for the narrative! Sounds like you had a good time figuring out all the parts. The center section of the string of icons is blanked out, usually with something like a strip of 35mm or smaller exposed/developed negative material. I think this area gets some other icon or instrument, like an outside air temperature indicatior, on models in Europe if it is ordered. I have had problems getting this piece back in place in the past.

The oil leak at the gage connection has bitten many of us, but it is not the only source of oil in the area. The vacuum lines to the starting switch can also be a source of oil.

Welcome to the board and thanks for the contribution. Photos always help, and you need to keep them below the 60 or 65 kB file size limit, and the maximum length/width screen size (800x600, I believe) and they post here just fine. Others post links to a separate web site with fewer restrictions when the photos do not convey the detail under the board size limits. Good luck, and thanks, Jim
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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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  #5  
Old 09-15-2003, 10:05 AM
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Congrats!

Once, many years ago, I took the cluster out of my '79 300D. I had to go somewhere while I still had it out and thought "what do I need the cluster for?". Well, I started up the car and got about 200 feet before I noticed my pats were pretty wet. You got it, I forgot about the oil line! I stuck my thumb over the line and tried to turn around in the parking lot and get back to my slot, but boy that oil was getting hot! I don't think I made it all the way back before I couldn't take it any more. Had to shut it donw and stick the cluster back in.

BTW. I've taken out clusters many times without tools. If you can grip it right with your fingers, you can pull out the cluster little by little until you can get a good hold of it and pull it out the rest of the way.
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'05 E320 CDI - 86,000 miles
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'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
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Old 09-15-2003, 01:38 PM
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Thumbs up

Thanks for your comments. I also think that failure to using the two wrenches to counter hold the oil pressure fitting is responsible for putting too much pressure on the flimsy screw fittings. On the three clusters I have seen the inside of, they all had at least one of these either stripped or split.

Any suggestions on how to repair or replace these plastic fittings with something stronger?

The driving in boiling oil sounded like quite an adventure! I am surprised to find no reference to this oil in the MB CDs. I wonder how many of us have learned about this "feature" through experience.

I will try and do some photos.... looks like there is plenty of interest and I will enjoy learning how to do it.

Am particularly proud of my technique of using the trip mileage shaft as a substitute for the odometer shaft while doing the repair. It works perfectly for pushing through the main one as it is the same.

Mr Goodfahrt
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Mr Goodfahrt (pronounced FAIRT... means "good trip" in German)

1982 300D Turbo Pastel Gray (off-white) 200k+(?)
newbie but willing
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Old 10-04-2003, 11:11 PM
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help with speedo rebuild

Mr. Goodfahrt:

I am looking at my speedo out on my desk

Can you help me with the post from the MBZ.org

Perhaps it may help me as it did you in your rebuild

So far I have the speedo out of cluster - where the cable mounts to the back of the speedo is off - not sure where to place my next turn of the screw driver

I too have black no.s

Please and thanks

peace
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nibiru
82 300TD- diggin it
Ich habe Dinge gesehen, die ihr Menchen niemal glauben würdet
Gigantische Schiffe, die brannten, draußen vor der Schulter des Orion
Und ich habe C-beams gesehen, glizernd im Dunkel, nahe dem Thannhäuser-Tor
All diese Momente werden verloren sein....in der Zeit
so wie...Tränen im Regen
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Old 10-06-2003, 12:56 AM
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Thumbs up

Sorry to take so long to answer. Here is the link to the MBZ article....

http://instrument.mbzarticles.org/odo/

There are 2 techniques described. I found it easier to push the the shaft out with the shaft for the trip mileage.

RepairFlix.com also have a good video you can get that shows some techniques that I found helpful. If you need someone to talk you through the procedure I'd be happy to do it by phone with you some evening. You've done the hard part by removing the cluster. E-mail me with your phone and we can set a time if you like.

Good Luck
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Mr Goodfahrt (pronounced FAIRT... means "good trip" in German)

1982 300D Turbo Pastel Gray (off-white) 200k+(?)
newbie but willing
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Old 03-12-2008, 12:09 AM
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Is there a new link?

Quote:
Originally Posted by Mr Goodfahrt View Post
Sorry to take so long to answer. Here is the link to the MBZ article....

http://instrument.mbzarticles.org/odo/

There are 2 techniques described. I found it easier to push the the shaft out with the shaft for the trip mileage.

RepairFlix.com also have a good video you can get that shows some techniques that I found helpful. If you need someone to talk you through the procedure I'd be happy to do it by phone with you some evening. You've done the hard part by removing the cluster. E-mail me with your phone and we can set a time if you like.

Good Luck
I found the above looking for help with repairing a non working tach and clock. The link given no longer works. Anyone know of a current link?
Charles
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  #10  
Old 03-12-2008, 12:45 AM
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this should do the trick!
http://dieselgiant.com/repairyourodometer.htm
and this part of the site has TONS of info for the car
http://dieselgiant.com/mercedes_diesel_maintenance_tips.htm
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Old 03-12-2008, 11:47 AM
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cheers thanks ya for posting this

I forgot about Dieselgiant.

Good luck

cheers:
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nibiru
82 300TD- diggin it
Ich habe Dinge gesehen, die ihr Menchen niemal glauben würdet
Gigantische Schiffe, die brannten, draußen vor der Schulter des Orion
Und ich habe C-beams gesehen, glizernd im Dunkel, nahe dem Thannhäuser-Tor
All diese Momente werden verloren sein....in der Zeit
so wie...Tränen im Regen
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Old 03-12-2008, 12:18 PM
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Too much to read!

Yes, thanks for the informative link. Only problem is how much time I now spend reading all of this great information. In my mind, I have fixed three of my car problems - I must now find time for the wrench.
Charles

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