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Question about accessing tailgate wiring harness in an '89 240 wagon 200

1. To get inside the headliner, grasp the edge of the headliner near a corner and pull straight back. The headliner is held on a thin metal strip, you'll see it when you pull back the headliner. You only need to pull back enough to reach the wires and bolts. Putting it back on is the reverse and easy.

2. I don't think there is enough slack in the wires to pull them up from the tailgate to reconnect to the harness above the place where they broke but you could try that. What I did was to get some electrical test lead wire (very flexible) and then splice this between the wires above the headliner down through the hinges to connect to the wires in the tailgate. I wasn't too happy with this. Everything works but the old wire in the harness did not want to take solder very well. I tried scraping the coating off, using extra flux, etc. The result was not up to my standard of a good solder connection. I used shrink wrap tubing to cover the splices.

3. Suggestions: New harnesses are not expensive when bought from some of the internet suppliers. You might be better off with new harnesses. Also, several on the BB have re-routed the harness wires out under a gap in the headliner and through the bolt access hole at the top of the tailgate. This avoids having wires in the hinges where they get pinched. I've seen photos of this and the job looks pretty neat. I may do that next time.

4. Be sure to check the black ground wires at the hinges. If you disturb the hinges be sure to reseal them carefully and get them back on in exactly the same position they were before. I marked position with masking tape, some use correcting fluid or markers. Also, only take off one hinge at a time and support the tailgate on a small step ladder.You'll have to release the two tailgate struts to do all this.

That's all I can remember for now. Post back if you have problems.






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