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No need to remove tailgate to replace rear wiring harnesses 200 1993

posted by  jthorner on  Wed Oct 4 12:55 CST 2006
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last visit: Mon Jan 4 04:02 CST 2010
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Most instructions for replacing failed rear wiring harnesses on the 240 wagon say to completely remove the tailgate. I've just done this job for the second time (two different 240s) and I never pull the tailgate off. I simply work on one side at a time. I use a step ladder with old towels as a support under the lip of the tailgate and do one side at a time. Personally I find this an easy way to go and it lets me do the job as a one-many operation. That tailgate is heavy and I just as soon leave it in place.

Both times I also found that the ground wire portion of the hinges had broken. I repaired these wires by cutting away most of the failed wire and soldering in a new length of wire between the two staked down terminal ends. Luckily I have a spool of high flexibility teflon insulated aircraft grade wire sitting around. This stuff should last a lot longer than the junk Volvo put there originally.

John





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