Rev counter problem

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mgrays
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Joined: 08.11.2005
Location: Aberdeen Scotland
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This is more for history.. would have put it on bottom of Bushman's email but search would not have picked up due to a typo in title.

So.. I have had a non functioning rev counter on my 300GD 460 1988 for ever .. it used to kick in once in a while. I had heard of the "cigarette butt fix" where they stuffed something soft above the circuit board and below the top cap.
http://www.pointedthree.com/disc/forums/showthread.php?tid=5047&posts=25...

So the other half claim she thought it was broken by her.. which was amusing as it's been dead for years! So I decided to fix it.

1. Remove the cap with circuit board
2. Prise the cap off the board - there is a bump on the lower loose section so just prise carefully around the edges so the loose part comes out
3. Then prise the circuit board with pins from the loose lower housing... it is all embedded in Silicon so be careful. There are 3 lower parts you can push the pin board off from underneath .. then a gentle working and picking will loosen silicon and you can work the top circuit board loose with it's 3 external clips.
4. Gently pick the silicon away from the pin retaining board so it becomes loose.
5. If you are lucky.. then you can just resolder where the wires go into the top of the pins. This is the only exposed part and corrosion starts into the exposed wire. Trouble is that the wire actually has screening (braided mesh) on under the very brittle external cover. Turns out this is not a problem in that the screening is not connected at the circuit board end but while unpicking the external cover tends to get damaged and I was not unconvinced that maybe some bits were rubbed to death inside the silicon
6. So… unpick most of the silicon .. slow slow job.. good hour at least going slowly. You also need to do this on the circuit board base where the tracks are.. I used a small brass bush, 1.5mm flat blade screwdriver and 0.5mm pencil to pick it clean. On the component side you only really need to clear around the wires and when unpicked you have a 50mm bit of wire so plenty of room. Watch out that the pins do not fall off the wires but to be honest the pin numbers are on the circuit board and on the socket on the car .. so you can rewire without this. I kept resoldering them on to keep them in order.
7. Replace the wires one by one. Braided/Screened wire is not needed and it is stuff with a diameter of 1mm for the outside diameter of the insulation so small stuff from Maplin etc.
8. Test it .. helps if you balance an old wing mirror on steering wheel to check while you wobble the wires
9. Repack .. I used Molykote Silicon Grease which may not be the best electrical solution but it is pretty inert, waterproof and does not set like the silicon sealant originally used.
10. Place pins in lower housing, then pin retaining plate is clipped in, then coil up the wires and clip circuit board into top of lower housing, Finally snap top cover on.
11. Reassemble and enjoy.

The long and short of it is that the soldering/wiring on the back of the pins fails..

Hopefully photos tell the story.. and I will have to see how it lasts..

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mgrays
mgrays's picture
Offline
Joined: 08.11.2005
Location: Aberdeen Scotland
GWOA Groups: Members
Re: Rev counter problem

And here is the circuit board drawing from the back with the pin numbers... ignore the glow plug relay on the bottom .. still working on that!