This is a very common problem.  In fact when people call me about 
problems with their window motor or door lock I tell them to look at 
these wires first.  Might be able get a new harness from VW if you are 
interested.  Or just repair yours with new wires.  I think the old 
wiring was just a little too short so it had the wires under a constant 
strain from day one.  Then add 22 years of opening and closing the door 
and you got your answer.  It is the coat hanger effect except extremely 
slow.  If you replace the wiring with new it should last another 22 
years.  I think that is an acceptable life span for anything mechanical.

Ken Wilford
John 3:16
www.vanagain.com

Arkady Mirvis wrote:
> Fellow listees,
>
> How common is the problem with wires breacking between the driver side door and the body? In my 1987 Westy the left door speaker isn't working and the window motor in the passenger side door doesn't operate the glass. I do suspect the wires are broken due frequent door on and off during many years. Recently I was offered by my friend to take any part I wanted from a burned down Westy. I took off the part of the harness between the driver side door and the body. 10 wires were broken! The insulation was hard as a rock! It is my opinion that the rubber around the harness is too short and should have been longer and going down. That way the harness would twist and last much longer. This can't be changed easily. I suspect that VW installs wires with same insulation for hot and cold climates. In the North, at sub-zero temperatures the insulation will crack and in that place the wire will break very soon. VW installed cheap wire with a few conductors. The right design would have been a fine, multi-conductor wire with flexible at all temperatures insulation. 
> Does anyone knows of the best type wire for eliminating wire breackage problem? If anyone had the problem, what was the method to correct it?  Thank in advance.
>
> Ark (the heaterman )
>
>