The tail gate hinge harness wires are cracking.

I found newly replaced hinges from a 1992 gold 240 wagon at a Portland junkyard in late 2006. Yet the ground wire between the roof and gate post broke some time ago.

Volvo used stranded copper conductor for the black ground hinge wires and the harness of four copper device wires on both sides.

I don't recall having any high-quality insulation wire with braided conductor to span a tightly hinged gap.

Read Art's replies here.
https://www.brickboard.com/RWD/index.htm?id=1638761&show_all=1

I've replaced these wires splicing them in, moved harness from under the roof back or from the tail gate up and forward. I've not performed this repair in the 21st century, though. My wiring and wrenching skills wane.

So, we have these from MTC:
http://www.partsgeek.com/catalog/1990/volvo/240/body_electrical/hatch_wiring_harness.html

We have options from FCP Euro:
https://www.fcpeuro.com/Volvo-parts/240/Tailgate?year=1990&e=914&m=142&page=1

Looking at the images, the Volvo Tailgate Wiring Harness Right has a close-up of the conductor at the crimp. The wire Volvo uses is stranded, yet a finer copper conductor strand.

OEM price here at FCP is about the same as Tasca. iPd is more expensive for both OEM and after market (MTC or Pro-Parts Sweden?).

I'm leaning to the Pro Parts Sweden from FCP Euro.

No garage or ladder to prop up the door. I have a folding ladder 50 miles away I'd have to fetch about 4.5-5 feet tall folded up.

Whaddya advse, please?

I have no sheathing. Yet would be nice to know a proper gauge and insulation type suitable for the hinge span. Else I'll chop in splice and run the wires from above the headliner down the interior side of the rear hatch into the space covered up at the bottom of the rear hatch.

To build the harness both sides from scratch with new connectors and sheathing would be in time and pice more than OEM from iPd of the local walk-in stealership.

Yet I guess I answered it already. Move up from the tail gate and splice in extra length. I also want to run on extra heavy conductor both sides for ground from the body, like at the tail light mounting post in a terminal ring crimped in.

Though the ground through the still in good shape hinges (they show no stretch at all yet) and the rear hatch latch seems to be fine.

And we have a giubo to replace.

On a 1990 (late 1989 just in last the 1990 wire) which will never be a proper restoration.

Drives it in ice storm and snow awaiting the collision to end it.

Li'l red wagon. Had it for 12 years, three months now.

The Made in Mexico Sachs Advantage from iPd struts I installed in 2012 are all but about failed. The same time installed 1992 240 GL Bilstein Touring are awesomeness. Both from iPd.

1992 240 GL feels like a very heavy 1975 BMW 2002.

Thanks,

MacDuff.
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