Wiring Bundle Repair

[Mike Veglia]

In a message dated 7/9/2002 Ken writes:

<< Does this repair just replace the broken wires with unbroken ones in the
same configuration?  Is there
anything to prevent a recurrence of the problem, with the wires breaking in
the same spot? >>

Good question. (Jeremy--could you please send me a copy of the parts list
you created?). In my '87 5ktq I have not had the problem yet in the driver's
door loom. This at nearly 200k miles old. I would suggest that doing the
repair once the right way will likely be the only time it needs to be done
in the normal lifetime of a type 44. There have been past discussions on the
mother list of spiral wrap, etc. to help minimize the problem. My 4kq has a
broken wire in the door loom I need to attend to BTW. This is a problem with
any car that runs wiring through hinged areas (trunk looms are also
vulnerable). Older low miles cars (implying many short trips) are perhaps
more at risk than those that had mostly highway miles--the failure is a
result of the number of times the door is used after all.

<< It seems to me that it's a stupid design (speaking of 5k's here, not sure
if the 200's are the same), having
all the wires flex in half, right at the hinge. >>

It's the price that is paid for electrical bells and whistles in the doors.
ovloV moved the window switches from the driver's door and put them in the
center console to help cure the problem--and then put an optional cup holder
right over the switches! :( The real solution truly is to get as much
electrical stuff out of the door as possible. Given the size of the wire
bundle going into a type 44 driver's door and the design of the door I
really don't see how it could be improved on much.

Mike Veglia
Motor Sport Visions Photography
http://www.motorsportvisions.com