Part 1 of How to remove your Instrument Cluster

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Please see my Gallery Photos as I am not sure why my photos aren't showing up with this post:
Hello. In this post you will find detailed information in Part 1 of two part series on how to remove your instrument cluster from 1991-1994 Model year Saturns.

This is a long post with alot of information; so if you have a dead odometer gear; this section of the post will show you how to get into the inside of your car to initially remove the instrument cluster that contains the gears.

Removing your Odometer Gears
Part 1 of 2

Part 1 – Removing the Instrument Cluster to get to the Odometer Gears.

Tools Needed:
Small 7MM Socket Wrench
Large Screwdriver
Small Screwdriver

Removing the Instrument Panel or Cluster: The removal of the Instrument Cluster is a very delicate job. You should take care and patience when performing this task. If you work through this fast you may run the risk of breaking something and then have another replacement on your hands. The replacement procedure is very detailed, so make sure you follow each step thoroughly. Good luck. Pictures attached will detail the steps as you go along. Some of these details are taken directly from the Saturn Service Manual Body/Collision Repair Section Page 476. If you have not done this before; plan on at least 2 hours total to get Part 1 of this procedure complete. Your time may vary based on experience with working on your car; and how your car parts behave to being removed. The procedure in the following photos was performed on a 1991 Saturn SC. The interior of your car may be similar or different; these photos are to show you the procedure in fixing your vehicle. These photos are for educational purpose.

1. Disconnect the Negative Battery Cable
2. Remove the bottom Left and Right Covers underneath the Middle Console Panel. (Photo 1)
3. Tilt your Steering Wheel down to it’s lowest position. This step will come in handy later on in removal of the Instrument Cluster.
4. Open both front doors of your vehicle (Coupe or Sedan) all the way; and prop them open if you need to.
5. Remove the endcap Cabin Air Panels. (Photo 2) These panels are on either side of the Driver side and Passenger side inside of the car doors. These are 7MM Bolts and each Endcap is held in by two of these bolts. Once you remove the endcap bolts you will need to remove the endcaps via a Flathead screwdriver. These snap in/snap out so be careful that you don’t break anything. You will hear loud crunching sounds, when you perform this operation. There is no need to panic; if you gently work your way through each of these steps; the parts will disengage with minimal ease. Once you have the endcaps out; there will be a foam inlay that may or may not be able to be reused.
6. Your sides should look like this: (Photos 3/4)
7. Remove your Cigarette Lighter Bezel. The Bezel will pop out fairly easy (Photo 5)

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Continued....

8. Remove your Center Trim Bezel. 2 pop outs on the bottom with your large flathead screwdriver and three pop outs on the top; and you have removed this piece all together.
9. Next, with your small screwdriver: Pry up the retaining clips on both sides of the dash. Using your smaller flathead screwdriver will yield the removal quicker. These are hard plastic pieces and will come up fairly quick to reveal two more 7 MM bolts; one on each side of the dash.
10. Undo the 7MM bolts. You should now be able to lift out the upper part of the dash.
11. Gently pry up on the upper part of the dash with your larger flathead screwdriver. There are 6 retaining clips that run across the front upper part of the upper dash. Pry carefully. Again you will hear a lot of loud crunching. The retaining clips will give way after some gentle tugging with hand and screwdriver. Some retaining clips will remain. Do not be alarmed as these will work their way back together on re-assembly.

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Continued....
12. I have a picture of what the dash looks like with the upper panel removed. Please see my gallery.
13. Remove the 4 remaining 7MM Bolts that are holding the Instrument Cluster in place.
14. Once these 4 retaining 7MM Bolts are removed you are ready to pull up on the instrument panel cluster bezel. Be careful! Your light dimmer switch on the left and Rear Defrost switch are still connected!!! If you pull too quickly you run the risk of separating wires. There are Green pin connectors that need to first be removed with your smaller flathead screwdriver. Once you have the Green pin connector free, squeeze on the remaining pins to remove the electrical connection for each electrical connection. This step can be tricky especially since the Light dimmer switch is surrounded by a half rectangular metal casing; and the wires for both switches are fairly short.
15. Begin removing the last 4 7MM Bolts that are visible around the Instrument Cluster.
16. In the back of your Instrument Cluster there is a large 2 Inch By 1 Inch Electrical Block connection. The electrical block connector are the set of wires that run everything on your instrument panel; so use caution when removing so as to not damage any wiring or connectors. Using your larger Flathead screwdriver; pry back the connection and your instrument cluster should lift out of the housing.
17. You have completed Part 1 of replacing your odometer gears.

[Low Saturn]

You can also get the cluster out of your car by looking on our website. Instructions have been there for quite some time.

1991-1994:
http://www.differentracing.com/tech_...94cluster.html

1995-1999:
http://www.differentracing.com/tech_...99cluster.html

2000-2002:
http://www.differentracing.com/tech_...02cluster.html

[brettkramer]

Thanks for the great info on how to get at your instrument cluster. The first time I had mine apart, I used my Haynes manual for info and it's ok, but I just ordered the Chilton Saturn Manual 1991-1998 because the Chilton manual just looks like it's more detailed. This summer I replaced all of the bulbs in the dash, plus my frayed drivers seat belt and my cracked drivers door panel, these cars seem pretty easy to work on once you did into it. It looks like you have 300K on your 94 SC1 which qualifies you for bragging rights. My question is, did you get to 300K without pulling the engine & trans for an overhaul? Is the car an automatic? My 1994 SW1 (Auto) has 168,000 miles on it and I'm wondering when the internal seals are going to wear out and when the timing chain is going to stretch to the point when I need to pull or replace the engine.

[geartooth94]

if you are at a junkyard and you are in a hurry, it's just 2 steps.

1) pry up upper round trim panel with flatblade and rip it away with gusto.
2) put both hands behind the cluster and rip it out with even more gusto.

done!

(only works on 1st gens)

[2NDSOUT]

Originally Posted by brettkramer

Thanks for the great info on how to get at your instrument cluster. The first time I had mine apart, I used my Haynes manual for info and it's ok, but I just ordered the Chilton Saturn Manual 1991-1998 because the Chilton manual just looks like it's more detailed. This summer I replaced all of the bulbs in the dash, plus my frayed drivers seat belt and my cracked drivers door panel, these cars seem pretty easy to work on once you did into it. It looks like you have 300K on your 94 SC1 which qualifies you for bragging rights. My question is, did you get to 300K without pulling the engine & trans for an overhaul? Is the car an automatic? My 1994 SW1 (Auto) has 168,000 miles on it and I'm wondering when the internal seals are going to wear out and when the timing chain is going to stretch to the point when I need to pull or replace the engine.

My engine/auto trans are all original...aside from the spark plugs/wiring replacing every 60,000 miles. I had to replace the timing chain back in 1999 as the people that owned the car before me ran the car a little into the ground....

All Highway mileage

2004: Replaced Original Alternator ($250)
2005: Replaced Original Radiator ($85)
2006: Replaced Original Water Pump ($75)
2007: In process of Replacing Original Odometer Gears ($25)

Cost: Priceless, when you consider the mileage....

Cheers!

[brettkramer]

Bryan, Thanks for the info, I've replaced everything you have and it seems like every couple of years I'm also looking at changing upper ball joint arms and tie rod ends as well, (the roads are bad here in Chicago). How did you know that it was time to change your timing chain, was it making an add noise? Do you remember the costs that were involved?

[JADEDSL2]

ROFL, when I removed the cluster (and dash) from my 93 in order to accomodate the new 99 SC2 dash and cluster, I used a 10LB hammer. Two simple steps.

1. Hit hard.
2. Repeat.

[2NDSOUT]

Originally Posted by brettkramer

Bryan, Thanks for the info, I've replaced everything you have and it seems like every couple of years I'm also looking at changing upper ball joint arms and tie rod ends as well, (the roads are bad here in Chicago). How did you know that it was time to change your timing chain, was it making an add noise? Do you remember the costs that were involved?

The car was making a rough running sound from the passenger side...like someone had run the car without oil for a week.

I had it repaired through the dealership (back in 1999....LONG before I know what I know now about Saturns....back then it cost me about $799 to do everything through the dealer)

If you can do it yourself I would reccomend it if you know what you are doing....otherwise it's the dealer or a 2nd hand shop....

[curls]

Is there a Part II? I can't find it. It would explain how to get into the odometer I would think. This is great stuff... I wanna read more!

[Crasoum]

Originally Posted by curls

Is there a Part II? I can't find it. It would explain how to get into the odometer I would think. This is great stuff... I wanna read more!

http://www.saturnfans.com/forums/sho...d.php?t=110569 I do believe

[curls]

Yep. Thanks !

[taugustine]

I replaced the odometer gear and put the cluster back in the car. I hooked up the battery to make sure the lights all worked. Everything was fine. I left the battery connected and when I went to screw in the instrumention panel, I lost all of the lights. Maybe I burned out a fuse or shorted out something? Any suggestions?

[Low Saturn]

Originally Posted by taugustine

Maybe I burned out a fuse or shorted out something?

Or the connector isnt all the way seated.

[curls]

Thank you for the great instructions!!! And pictures.

The site went down just as I started so, I did some guessing (I'd read them a few times). I was able to get the cluster out by taking off only two pieces -- the plastic around it that have the dimmer & rear defroster connections, & the dash cover. I took off the middle bezel & driver side vent, but doesn't seem like I needed to. It's a '92 & on the passenger side the dash cover clip is broken already, so maybe that's why I could get away with much less?

I had trouble detaching the electrical harnesses for the dimmer & defroster until I tried a needle nose plyer to push down the tab while pushing it all out. There weren't any green pin connectors on this one.

Since everything was harnesses I didn't disconnect the battery, though I probably should have.