1993 Volvo 240 broken wires drivers door boot

[lionhearted]

Would somebody know best way to fix broken wires in left front door boot between body and the door? I tried holding boot back, but not working. can't get enough room to do repair. I have 3 broken wires. Cut boot with razor blade? Thank You Richard (1993 Volvo 240)

 

[KeizerBrickGuy]

I would pull the door and repair it as needed. It will also give you a chance to clean/lube the door check and latch linkage.

 

[lionhearted]

Disconnect electrical components in door then drag them through?

 

[cleanflametrap]

I've done this before and had no thought of removing the door (nor any desire to realign one) but most of the same access is needed: Working behind the fuse panel, you'll see where the bundle exits the tunnel. I believe each of the harness extensions have connectors that will pull through the "boot." That way you can put fresh wire inside the joint and make the splices where there's no stress. It is easy to tell which wires suffered if you pull them a bit and see the insulation stretching where the wires are broken inside.

Edit: I recall using an old speedometer cable insert as a fish to pull the repaired wires back through.

 

[nel621]

First disconnect battery. Next remove fuse panel. Now carefully peal back black paper insulation. Oh, you may need to remove the kick panel where the fuse bar lives. Now you're going to want to pull the wires into the cabin. They won't move. There is a big clip holding it all together, find and remove that. Now isolated the wires you want to repair. Keep in mind that the wires don't travel horizontally. They kind of go up and over to the hole in the jam.

 

[VB242]

Buy some good quality SO 3 conductor cord and pull that through and connect the ends at their respective locations.

 

[lionhearted]

Thank You All, Don't understand why wires broke, its only got about 330,000 miles on it.(just kidding, but not about the mileage) Must have been lucky on the other 3 that I had.

 

[lionhearted]

First disconnect battery. Next remove fuse panel. Now carefully peal back black paper insulation. Oh, you may need to remove the kick panel where the fuse bar lives. Now you're going to want to pull the wires into the cabin. They won't move. There is a big clip holding it all together, find and remove that. Now isolated the wires you want to repair. Keep in mind that the wires don't travel horizontally. They kind of go up and over to the hole in the jam.

Thank you, Richard