05 Outback other day, noticed that the rear hatch handle wasn't returning after opening. Assumed some cruddy rust situation and sprayed some rust relief/ lubricant on either side of the handle since access would seem to require disassembling way too much.. Next day all seemed ok.

Now the curious coincidence or cause of the original handle not returning??

Today, I noticed that the hatch wasn't locking/unlocking either from the door switch or the key fob.

Found a post describing broken wire in the left harness at the top of the hatch coming from the body to the hatch and sure enough, thar she blows!

Anyone who tackled this issue care to suggest best way to mend the wire? Simple solder and shrink wrap would seem to be the easiest since I am afraid of shortening the wire at all and am also concerned about the bulk of a crimp connector?

Overthinking it??

 

Solder. Maybe a short piece of bare similar stranding to tie the ends together without shortening it. Shrink tubing. With electronic rtv to seal it if it is exposed to the elements.

I hate solder on stranded automotive applications. It's not flexible, and the heat can be very hard on the wire. I only use Molex PermaSeal adhesive heat shrink butt splices (I purchase them in bulk on Waytek wire), as they're tough, but slightly flexible.

 

Also, all those wires are brittle. So at the very least, replace the entire exposed section of that broken wire. I work at a dealership, and when paying labor, it's just not worth it to try to repair these, usually when you start messing with them, adjacent wires start breaking, and the time starts adding up fast. We stock the rear gate harnesses for them. They're usually about $75, which is a chunk of money, but I'd be tempted to do it that way and be done with it!

update:

finally got around to soldering that broken black wire in the left side but that didn't fix the issue.

took a closer look on the right side bundle of wires coming from the body to the hatch and there were two wires broken in this harness

the wires broke very close to the body so I had to pull the wires out of the rubber boot to be able to solder another piece of wwire into the mix but now it works fine

Edited May 8, 20178 yr by brus brother

Like dental work !

Nice job Jim.

 

Nice car meet up in North Salem NY these days if you ever get that old 360 out on a Sunday. First Sunday every month. Hayfields Market/coffee shop. No Caffeine and Carbs this year.

Cheers!

Like dental work !

Nice job Jim.

 

Nice car meet up in North Salem NY these days if you ever get that old 360 out on a Sunday. First Sunday every month. Hayfields Market/coffee shop. No Caffeine and Carbs this year.

Cheers!

yup except no xrays. Had to perform exploratory surgery. ;-)