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NAJ, I apologize for it taking so long to get to this. I figured out how to get it apart without "breaking" it, but the design is rather ridiculous.

Step 1, remove the speed unit from the cluster. I trust we all know how to do that.

Step 2, remove the needle from the unit. You have to twist the needle around to the right until you hit the stop, then gently keep turning it. The needle will start to spin on the axle. At this point, continue to gently turn to the right (clockwise) while also gently pulling up. The needle will slide off the end of the axle.

Step 3, and this is the stupid part, you have to peel off the plastic face plate from the front of the unit. Get a small pick or flat screwdriver and gently pry the black plastic face plate away from the clear acrylic base it's glued to. If you take your time and the plastic isn't too brittle, it should separate. You might need to coax the glue with some heat. I managed to get mine off without breaking it.

Step 4, disconnect the trip reset button from the metal pin. It just clips on.

Step 5, remove the 3 standard-head screws shown in the picture below. They are very small and you need to be gentle taking them out and putting them back so you don't crack the acrylic base.

Once the screws are out, the entire speed driver/odometer assembly will just fall off. Then you can access the screws for the circuit board and replace the gears.

I haven't tried putting it back together yet, so if anyone wants to give it a whirl and report the results of re-attaching the face plate, that would be awesome.

Fun note, the speedo unit in my car is not the original. I had the original (pictured) tucked away in a cabinet because the odometer stopped working. Why? I don't know because the gear is intact. The unit in my car is the later model NipponDenso that I swapped in '04 because it was very close to what the original was showing and I liked the design better. The trip odometer on the ND unit doesn't work because the plastic tabs that hold the trip odometer gears in place broke and the metal bar and gears were laying in the bottom of the unit. All the gears are intact, I just need to replace the reset mechanism which also holds everything in place.

 

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I've known how to disassemble the 90+ speedos for a long time. It's putting them back together that is more difficult. I don't know what adhesive to use for the gauge face that won't show through, melt the plastic, or cause the backlighting to be funky...all without it peeling back off over time.
 

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