I removed the dash on a 1985 W123, to check the climate control system, but can't get it back in. I read some detailed post about removing it, with a very brief explanation of how to reinsert it, but it didn't really explain how difficult a job installing it is. I just kind of was hoping someone had a technique that worked for them. Otherwise, this is a warning to not remove the dash unless you don't plan on putting it back in. This is a very hard thing to do. I tried for an hour to get it in without breaking it, then I spent an hour trying to get it in with no care to damaging it, and still couldn't get do it.

I find it helps to let the steering wheel down (or take it off).

X2 you will need to remove the steering wheel for additional clearance.

I actually did this last month on 1983 240D. Here's my situation and my advice...


I've been spending the last 3 years patching up and fixing up an '83 240D in my garage (I have yet to drive it - long story, personal reasons...). I bought the car because it was a 4-speed car with a functional engine and transmission. The body wasn't great (had to do more welding on the passenger side floor and rocker than I originally thought, but the driver side really was pretty solid). Now that the bodywork is done, I'm working on the interior.

I picked up a '79 240D parts car last year that's the source of my new interior. The '83's interior was trashed. The carpets were gone, the dashboard was all torn up (previous owner's dog bit chunks out of it, I think?), and the driver's seat was similarly torn up.

So, last month, I replaced the dashboard with the one from the '79. Getting the old dash out wasn't too bad, but fitting the new one was a pain. Eventually, I realized that I was having a lot of trouble getting the foam lip on the front of the replacement dashboard to slip under the windshield seal.

I took the '79 dash completely out again and carefully trimmed back the foam lip on the front of the '79 dash. Doing so helped me slot in the "new" dash without a problem. Once the dash was in, I couldn't see where I trimmed it. Since the '79 dash was cracked a bit anyway, I didn't worry too much about damaging it. Once it was in, I filled the cracks, and it still looks 1000% better than the old '83 dash.

And yes, take the steering wheel out. It helps a lot, but I had issues getting the new dash in even with the wheel off.

Wondering what you used to fill the cracks in with?

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Rebe

I've removed and installed several 123 dashes. It's definitely a fight to get back in. Removing the steering wheel is very helpful. Also make sure you put the back edge of the dash in first. There is a lip on the dash that has to tuck under the windshield seal. If you don't get that in the rest will never fit. It is also helpful to remove the A-pillar trim pieces.

Get the dash lined up and sitting roughly where you want it. Then work in that back lip of the dash. Then it should all sit down easily.

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It helps to use a paint stir stick to work the lip under the windshield seal. My first dash install turned into a disaster on my CD, and I cracked the windshield. It would have been cheaper for me to have the windshield removed first, and then install the dash. I learned the hard way, as a coupe windshield is expensive! Anyway, patience is the best attribute to employ if you are trying to install a dash with the windshield in place....Rich

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

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I took the dash out of a scrapped 1982 D once. Removal was not all that hard. But, the farther I went, the more glad I was I was that I was NOT going to be re-installing it.
-c-

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"I applaud your elaborate system of denial"

It's a '79 dash, so it's black rather than that dark brown/charcoal-that-looks-like-black in the later W123s. As such, I used black RTV. You can see where I filled them, but it's nowhere near as obvious, especially from a distance.

I have the steering wheel off, and the pillars too. It seems like the dash wont go in straight, as it is wider than the space it's going into. Then you have to get it to sit down over the air vents in the center. I'll try to trim it a little on the lip, but I can't even get to that part of the problem yet, 'cause it won't all go up flush against the window...yet Seriously, removing and re-installing the windshield may be the answer, especially if you care about cracking an old dash that is in good shape.

As for the air vents, I make sure that I have the glove box completely removed and work the dash onto the vents and vent linkage through the glove box opening.

I Messed around with it some more today, and it's not working out for me. I think I'm going to try and find a glass shop and ask them to pull the windshield, and re-install. It can't be more than $60. Just waiting for the rain to pass this week.

Dashes in general can be a pita when doing them by yourself. Much easier when you have an extra pair of hands. I find that a rest and 2nd look also helps. Be sure to do everything that you want to while the dash is out. ie repair or replace vacuum pods, decide whether the evaporator and heater core should be replaced, remove whatever cruise parts need to be repaired, understand & refurbish shifter lights and dash lights etc.

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.

I got it in by myself! This would have been a lot easier with 2 people for sure.

2 things really helped. I hot-glued the insulation in place, 'cause it was loose and interfering then I used some strips of 1/16" lauan plywood on the front lip, about 8 pieces spaced across the front. Then I just pushed it straight in while guiding the center vents on. Took me about 20 minutes. Thanks for the tips!

Thank you for the tip on using the the thin wood veneer spaced out to guide the lip - taking Rollguy's suggestion yet a step further. I plan to replace the dash on my W126 and this sounds like the way to go. Another example of how ideas evolve, and how sharing them on this forum is so useful.