Instrument Cluster, 2002 S80 & Others

[IdahoBob]

I need some advice from some of you rocket scientists before I spend some $ throwing parts at my S80:
My 2002 S80 (202K miles, 2.9L non-turbo) has developed a flaky instrument cluster.
Symptoms:
1) Odometer & trip odo are just dead/invisible; nothing in that little box even tries to light up.
2) There are vertical areas through the cluster that are dimmer than the vertical areas between them.
3) The whole enchilada just goes dark and the needles all peg themselves at "0", instantly, intermittantly (more frequently "off" than "on".
4) I can bang on the dash and get thingies to light up and speed, etc. to register, for a few seconds (longer when car is real cold (below freezing outside now), but only for a fraction of a second when it's warm.
I carefully pulled the cluster out, checked for nicked wires, opened it up to look for obviously broken wires, circuit lines (a fuse maybe!, None!) No luck. Checked for loose relays, oxidized fuses, mystery unrelated blown fuses, etc. Nada.
I called the dealers here in Denver. One gave the predictable answer: "We can fix it for about $1400." and told me I couldn't use a used one because the odo wouldn't be right. The other one said they could sync up a used one for me, but the odo wouldn't be right, and it would cost me $115.
OK, the questions:
1) Will a used one work, with or w/o dealer help? If the odo is going to be wrong anyway, what are they programming?
2) What years & models will work? Will all 2002's of the same size (S80, XC70, V70, etc.) work? Will other years work?
3) Does this really sound like a dead cluster, or should I be checking something else first?
Thanks!

[randyman]

I have an 2002 S60 that just started the same thing a couple weeks ago. It was -20F the other day here in Buffalo so i have been putting off any troubleshooting, but don't think it's the inst. cluster automatically. I saw info about wire chaffing on a metal bracket (I assume between the cluster and the fuse box inside the car). I found that if I release the locking lever to adjust the steering column and move it, the cluster will come to life for a fair amount of time. I think it is a wiring harness issue down below. I will TS when warmer. Another could be a worn ignition switch. I saw that on this site as well, and ran into it as a tech on some GM vehicles in the past. I do not think the cluster is faulty on mine, at least not yet!