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removing wires from wiring harness

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America). P2 platform.
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dkellogg3
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Year and Model: 2007 3.2 XC90
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removing wires from wiring harness

Post by dkellogg3 »

So I have the left blinker/driver door open issue due to a broken wire. It's the back wire right at the harness that clips to the door. Needs to remove the remnants of the wire and the pin. Any help on how to get the pin to release?

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BBowen6123
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Joined: 21 July 2016
Year and Model: 2003 XC90
Location: Minnesota

Post by BBowen6123 »

I have EXACTLY the same problem as your pictures show. Did you ever find a resolution?
If so, let me know on this post. Minnesota Bruce

rsnuke
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Year and Model: 2010 XC90
Location: Montreal

Post by rsnuke »

I have the same issue... how did you pop out those metal inserts out from the plug? so i can solder a new wire?

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volvolugnut  
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Post by volvolugnut »

There are pin removal tools you use for this job. Try search on Amazon. Get a set of them since you won't know which one you need.
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Post by abscate »

RickHaleparker had a thread here on thst with links, I’ll try to find it
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cn90  
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Post by cn90 »

Below link is a very good video. Once you understand how this is designed, then it is easy. Now if you carefully remove the remaining female end and gently pry it open to remove the broken wire, you may be able to re-use it. Of course, if you can find brand-new identical female end, then use it.

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ggleavitt
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Post by ggleavitt »

Good view of the pin removal. One challenge may be the new connection. You'll really want a new crimp on the connector which may mean some new wire and a splice. If you end up going in this direction, make the new wire that crimps to the pin/socket as long as possible (like 1 inch?) and connect to the old wire with some good heat shrink and preferably a solder joint in the rubber passage between dorr and front quarter. You're wanting to get the new wire in the connector for a solid mechanical fit but keep the flex point of the splice itself farther back. Hope I'm explaining this correctly. One alternative is to drill out the pin/socket and run a single piece of wire throught the nylon connector body and splice on either side of the connector but I'll guess that takes some skill to avoid the other conductors in the connector body.
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cn90  
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Post by cn90 »

One problem w door wiring loom...once a wire is broken, others follow soon.

So...best is to get a new wiring loom.
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packetfire
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Post by packetfire »

Here's a tool kit that will do for $6

https://www.amazon.com/DINYO-Upgraded-T ... B0DQNMKHY7
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