89, 245 DL
153,000


Just replaced the tailgate hinge wiring.

The ground wires in the left hinge is broken, and the right is hanging on by a thread. Both ground wires are stiff (no longer flexible), the wires have turned black and corroded. Splicing is not an option.

Are these available from Volvo? But, I would rather replace the wire with flexible test lead wire and new connectors - But are the odd squarish shaped connectors even available? ... and do they need a special tool to push them down onto those squarish shaped posts in the hinge body?

I removed the connectors and was not able to get them back onto the posts. I also tried soldering them and the solder won't stick (must be aluminum, stainless, or chromium compound - doubt it is magnesium or titanium). So, unless it is aluminum and I can use a special solder, then I will need to be able to find and install new connectors.

Also, the wire gauge looks to be a 12 or 14 gauge wire, much thicker than the harness wires. Is it important to stay with the same gauge, and if yes then is test lead wire not an option?

Oddly, everything is now working again, upper brake light, wipers, locks. Guess the hinges themselves ground it (?) However, the one right side hinge ground wire was not completely severed (I temporarily soldered the partial break) and so that may be what is providing the ground for the system (I was told that only one good grounded hinge is needed).

I would prefer to have the ground wires rather than not. Any recommendations?


diyer89, 245 DL
153,000


Just replaced the tailgate hinge wiring.

The ground wires in the left hinge is broken, and the right is hanging on by a thread. Both ground wires are stiff (no longer flexible), the wires have turned black and corroded. Splicing is not an option.

Are these available from Volvo? But, I would rather replace the wire with flexible test lead wire and new connectors - But are the odd squarish shaped connectors even available? ... and do they need a special tool to push them down onto those squarish shaped posts in the hinge body?

I removed the connectors and was not able to get them back onto the posts. I also tried soldering them and the solder won't stick (must be aluminum, stainless, or chromium compound - doubt it is magnesium or titanium). So, unless it is aluminum and I can use a special solder, then I will need to be able to find and install new connectors.

Also, the wire gauge looks to be a 12 or 14 gauge wire, much thicker than the harness wires. Is it important to stay with the same gauge, and if yes then is test lead wire not an option?

Oddly, everything is now working again, upper brake light, wipers, locks. Guess the hinges themselves ground it (?) However, the one right side hinge ground wire was not completely severed (I temporarily soldered the partial break) and so that may be what is providing the ground for the system (I was told that only one good grounded hinge is needed).

I would prefer to have the ground wires rather than not. Any recommendations?


diyer