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R Gauge Install...(photo intensive)

18409 Views 51 Replies 16 Participants Last post by  Mika
Once I realized that the R cluster (from a 2004) won't function in the T5 (2001), I wasn't going to waste a perfectly good cluster. Last night I decided that I was going to swap out the parts from the R cluster into the T5 and see what happens. From what I know, the only other person to do this was S60Evolve from Sweden. This install is not complete but the majority of the work is done. I still need to change out the LED's from the yellowish colored ones to brighter white ones, or possible blue. I have not decided yet. On to the pics and descriptions!

1) A side by side comparison of the clusters.

2) The outer bezel and plastic cover are all held by clips around the cluster. Just use a screwdriver to carefully pry them loose.

3) Once the shrouds are removed, this is what the clusters look like inside. Still look pretty much the same.

4) In order to remove the gauge faces, the needles need to be taken off. Be careful with this step as the guage face itself can be scratched by whatever tool you use. I chose a fork.

5) With the needles off, 2 screws hold the face of the gauge on. When removed, the faces can be removed from the cluster.

6) When the front of the face is removed this is the piece behind it (T5 shown). The center part that looks like an orange square is wrapped in extremely thin copper wire.

7) These are the R gauge faces installed in the T5 cluster.

8) This part of the R shroud needs to be cut away before clipping it back into the T5 cluster. I broke a clip trying to get it to fit before I realized that this piece was keeping the two from fitting together flushly.
On the R cluster, this just acts as a channel for the upper lighting wires.

9) With the shroud installed.

10) With the plastic shield installed.

11) The lights on top of the cluster. I have yet to figure out how to power these, which is where I need someones help that is good with wiring.

12) This is the connector that comes off of the lights. I am assuming it just needs a 12 V power source but I am unsure of what I need to do to ground it or if any relays will be needed.

13) This is when I first reinstalled the cluster and tested the lights. Everything works, but the lights are more of a yellowish than white. Due to the nature of the bulbs, there is a HUGE bright spot in the cluster and I am unsure of how to remedy that without major work. I think once I get the front illumination working it will not show as bad as it is right now. S60Evolve had the same issue, except he used blue LED's instead of white. I am unsure of which ones I will try.

14) The needles need to be adjusted. WHen I was driving they weren't reading quite right, so I think I may have pushed them down a little too far. I will check it out when I take it apart again this weekend.

15) Quick day shot I just took while at work...kind of dark but they look nice.

16) Just a quick shot while I was out there of the aluminum mesh door blades that I put in last week.

So this is where I stand right now. I am going to order some bulbs today to replace the stock lighting. I need help with the wiring of the top lights if anyone has any experience with wiring and can help me out, I would be very grateful. So comment/criticize/flame away. Thanks for checking this out! http://********************/smile/emthup.gif


Modified by S60Driven at 8:37 AM 7-12-2006
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WOW, you resized the pics just when they were done loading on my narrowband connection

Your project is looking real good, might want to bring your car in the dealer for your SRS warning and next time DC your battery when you are going to remove anything.... Good luck (I would go with xenon or blue LEDS
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by the way radioshack and others have these cool universal remotes so you dont have to have 40 on your table
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Talk to Jon at Boston Volvo..... he can hook you up

-The Copeanator
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