Trunk wiring harness repair - some notes - Saab 9-5 Bulletin Board - Saabnet.com
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Trunk wiring harness repair - some notes
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Posted by westernny [Email] (more from westernny) on Tue, 2 May 2017 13:53:01 Share Post by Email
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I finally got around to fixing my inop backup lights and a brake light weirdness. I had a look at the DIY page that's referenced elsewhere on this bb - see the link below. There are a couple of things I discovered that perhaps aren't exactly clear in that otherwise very good tutorial.

1.) If you try to TWIST - HARD - the plastic elbow that fits into the trunk lid, it will most likely break. My Aero is a 2001, and that fitting was very brittle. The solution is to firmly SQUEEZE the lower sides of the squared-off end underneath the rubber gasket (i.e., the end closest to the edge of the trunk...) The fitting itself uses a compression-type set of tabs, one on each side. It is not angled/bayoneted into the hole in the trunk in any way.

2.) It's true that Saab saw fit to include 3 separate green wires in this harness. One is obviously of a smaller gauge that the other two. The other two, however are NOT identical in gauge - one is a tiny bit smaller, which you can see if you look really closely. So, if you've got more than one broken green wire, no need to worry about which one goes where. Just take a really close look at the wire gauges.

3.) All of the wire breaks/partial breaks in my harness were at the point shown in the DIY. I merely tagged them all with wire markers, cut and pulled the broken ends down through the hard plastic tube and rubber sleeve. I spliced in new 18 gauge wire, threaded the new pieces back up to the elbow, solder/heat shrink tubing on those ends, and tucked the (now) extra wire back up through the hole in the trunk. Stuck a tie-wrap around the trunk end of the wire bundle, and buttoned everything up.

4.)The point is, I think disassembling the entire wire harness from the trunk is unnecessary, as there will likely not be any wire breaks insde the trunk lid itself.

HTH

posted by 50.48.170...

Saab 9-5 trunk harness repair


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