Volvo: Electrical problem on 240 wagon, door hinge, electrical harness

Question
I have a 92 240 wagon. I have a problem with the portion of the electrical harness that runs through the wagon hatch hinges. The wires keep getting severed where they run through the hinges of the hatch. Is there a service bulletin about this problem? I have had the problem serviced twice before but still the wires get damaged by the hinge movement. As a result have problems with various electrical intruments and indicators. Any suggestions would be appreciated.

Answer
There were two severe issues with the rear door hinge wires.  One was that in older vehicles, the wires were actually exposed to the sun, causing rot after just a few years.  I believe in your model this isn't a problem, though, I think they fixed the hinge by 1992.  Correct me if I'm wrong.

The other issue is the use of less flexible wires that break after repeated opening and shutting of the door, with bends them 90 degrees, then back down again.  I had to replace these wires on my wagon as well, and I found the key was to get wires with sufficient flex, like spun wires rather than solid core for instance.  Something like speaker wire would work.  It's possible that when they repaired it the first time, they used a wire that didn't take well to bending.  Something like a moderately high quality 24 gauge spun copper wire should work well.  Good luck!