Trunk Wiring Repair, Use the Right Wire - Saab 9-5 Bulletin Board - Saabnet.com
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Trunk Wiring Repair, Use the Right Wire
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Posted by Bill N [Email] (more from Bill N) on Tue, 3 Jan 2023 15:00:54
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The wiring going into the trunk lid on just about every 9-5 breaks where it flexes. In addition to the lights not working, it can cause other odd electrical problems depending on what gets shorted.
The fix, as many others have noted, is to splice in new wire to replace the broken segments. However, the new wire will usually break in due course unless wire intended to survive repeated flexing is used (something Saab obviously did not use). This wire is made of many more fine pieces of wire than normal wire so it remains flexible. It is often referred to as continuous flex or ultra flex wire.
I found BNTECHGO ultra flexible wire on Amazon. 18 gauge works well. It comes in a bundle of 10 pieces of different colors. I'm sure there are other sources and brands.
The job is easier if the wiring harness is removed from the trunk lid. Feed the replacement wires through one at a time, solder the splices and cover with shrink tubing. Be sure to provide a few extra inches of length to make reinstallation easier.
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