I know, this has been covered before many times, but I want an 'easy' fix. It looks like I might have to pull the seat out of the car anyway.

The red wire to the thermostat was hanging down from the seat. I unplugged the remaining wire. Seems the red wire was pulled out of the plastic plug. The red/white wire could be an inch longer, I suppose.

QUESTION: How do I take the plug apart and get new wire to the female connector inside the plastic plug? Is that black tape holding the two parts of the plug together?

I really don't want to pull the seat out if I don't have to. Kneeling on the floor with my head stuck under the seat isn't fun either!!

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My back feels better when I sit in a Volvo seat

The reason I like the Brickboard is because I like problem solving.

Remember the drill bit? I happened to have a 1/16 bit. So I drilled out the copper wire from the connector, inserted the new wire and crimped/soldered it in place.

I also added 2 inches to both thermostat wires, perhaps that will help.

It is always nice to not buy parts!

When it gets cold, I might try out the heated seat. At the current 90F, it won't do anything.
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My back feels better when I sit in a Volvo seat

Good for you, Klaus. Yes, DIY is quite satisfying, and without driving all over. I am in the midst of a chainsaw oiler pump issue, which is for another bulletin board and would be a lot of fun if I didn't have 10 other broken things to fix. Like the lamp monitor which is back on in the S70 due to some grounding issues at the inboard lights.

It's always something. Now you can enjoy your seat heaters. You're the early bird that gets the worm. I didn't order wood for heating this spring because I was hoping to have moved. I'm jealous.

The red wire broke at the female plug, inside the plastic holder. The two holders are taped together. The yellow/orange wire is also showing signs of pending failure, the sheathing is cracking in multiple spots at the base of the plug.

I was able to get the female connector out of the plastic, easy. But the clamp that holds the copper strands won't give up the copper. I see no way that the clamp can be relaxed, yet. Perhaps a very small drill bit to drill out the copper, and then a nail to expand the aluminum holder?

I do have spare wire so I can add a couple of inches to both existing wires.

The last time I looked, auto parts stores did't have the correct spade connectors.
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My back feels better when I sit in a Volvo seat

Klaus - You've given lots of background, but for someone like me not familiar with this specific failure, it sounds like your problem boils down to a wire crimped into a terminal broke at the terminal. You would like to reuse the terminal, which you have extracted from the connector body. Is this close?

I have no suggestion for you, unfortunately. I have bit a lot of electro-mechanical work, and enjoy mechanical challenges (other than working on emergency brakes). I've tried to "uncrimp" wiring connectors using different techniques like prying, drilling, etc, with marginal or no success.

What about finding a car with that harness at the pick and pull, and cutting the end of it off? You seem to know where the places are that stock carcasses, to satisfy your hobby.

There are 2 P&P lots, one southeast of the TwinCities, the other north. Either one is a 45 minute drive. So, gasoline to get there, $2 to get through the door, shoes required (it's 90F in the shade, and they have no shade), and then pay them $2-5 for the thermostat? Fixing it myself, at home, is much more satisfying.

I do have to get to the P&P, but I am looking for roof rails, possible front fenders, window washer nozzles that spray, and bits of hard to find trim. Serious money stuff!
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My back feels better when I sit in a Volvo seat