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From the new, unpublished FAQ:
Engine Service Reset Button. Often the "engine service" light reset button can make the trip odometer gears stick. Punch this several times to free it up.
Repairing Non-Working Odometer. [Tip from Mark] At some point during your 700/900 series Volvo’s life, its odometer may cease to function. I believe the gears jam or break due to people resetting the odometers while the car is moving. If only the odometer (cumulative mileage and trip) has stopped and the speedometer still works properly, do not fret. An easy and cheap solution is readily available. What has happened with your odometer is the gears that turn number barrels have become jammed. The usual culprit, according to the owner of speedometer shop I spoke with, is the set of gears that operate the service reminder light decided to be stubborn and constipate the entire odometer show. Because the guy in at the speedometer shop was so confident about what caused the problem and how easy it was to fix I decided I would try to save my self a few bucks. I got quotes ranging from $95 to $220 to fix the odometer if I removed the gauge cluster from the car and brought it to them. I ended up fixing the jammed odometer for less than 2 dollars. Here is how I did it:
Remove the gauge cluster from the dashboard. Directions to remove the trim panel to access the screws holding the gauge cluster in place can be found in the 700\900 FAQ. If your car is a turbo I strongly suggest cutting the vacuum line to the boost gauge 3 to 4 inches from where the tube connects to the rear of the gauge cluster. These small hoses harden over the years and I was terrified that I would break the hose nipple off trying to remove the vacuum tube. I went to the local parts house and purchased a package of barbed vacuum hose connectors for less than 2 bucks to reattach the cut hose. This way I did not have to worry about doing any expensive and troublesome damage to the boost gauge.
Once the cluster has been removed locate the five or six screws that hold the clear bezel to the front of the gauge cluster. The screws that hold the bezel on are the biggest ones on the back of the cluster. If you try this please take a moment to study the panel before removing screws. In addition to removing the screws, you will have to unclip or detach a couple of small plastic parts around the edge of the cluster. I wish I could be more specific but it has been a while since I fixed mine. It is not difficult. You just want to take the time to be careful and attentive to details. Once the clear bezel has been removed, use the eraser end of a pencil, or some other object that will not scratch the number barrels of the odometer, to carefully advance the odometer past the point where it has stuck. See below if you need to replace the gear. Reassemble and drive happy.
Replacing Odometer. I have found a solution: at the pick and pull I can get an instrument cluster for very cheap (10-25% of the repair estimates). I just unscrew 8 screws at the back of the board and remove the cowl and lens. Then take 4 screws out of the white speedo housing to pull it free. This can be transplanted easily into your recipient cluster and even a slightly different 1990 model works well in the 86 cluster after removing the service reminder reset cable that the later ones come with. Who needs that function anyway? To reset the mileage to your correct (but by now estimated) figure is also trivial once you remove the small white electric motor that drives the odometer, and slide the pin holding the small exposed gears. The odometer digits now rotate freely. No cheating at this point. Most of the speed-odometers are the r9800 variant but compatibility is something to check for in the replacement. Apparently, this number keys it to the rear end properly. This is also a swell time to throw in a large tach if you can get one.
Replacement Gears and Parts. Your odometer is mechanical. See http://www.odometergears.com/ for parts and supplies.[Another Tip] VDO in Winchester, VA, and other places advertise. Get a copy of Hemmings motor news, you will find them in there. [Editor] IPD now sells for $50 a complete odometer repair kit along with a DVD showing the repair procedure.
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