E91/E61 glass tailgate issues

[Burrito]

My rear window/glass hatch keeps popping open and I’m struggling to fix it.

It appears to be a regular issue on both e91 and e61s that’s usually solved by either replacing the glass-hatch button, or repairing damaged wiring in the loom where it comes through the join between the body and the hatch.

I’ve done both of these and still having problems. So decided to take permanent action and remove power to the latch mechanism. Unfortunately I think there’s some kind of sensor/feedback which stops the rear wiper function if the glass hatch appears to be open, there’s definitely a microswitch in the mechanism but I don’t know if this is a limit switch for the latch or is is breaking a circuit which allows the wiper to run...

Can anyone shed any light or throw me a bone, as I’m out of (limited) ideas.

This latch:


This mechanism:


This micro switch:


These cables are what feed the mechanism:

[Elliot2000]

When does it pop open? Is it when u unlock the door or when you turn the ignition on?

[largespiced]

I disconnected the plug under the spoiler. This stopped it. Wiper still worked but heated screen didn’t. Bloody poor design on (in my view) a pretty bad overall car!

[Burrito]

Elliot2000 said:

When does it pop open? Is it when u unlock the door or when you turn the ignition on?

When I unlock and within around 30 seconds of starting the engine (if I don’t hit the internal lock or the auto lock applies)

[Burrito]

largespiced said:

I disconnected the plug under the spoiler. This stopped it. Wiper still worked but heated screen didn’t. Bloody poor design on (in my view) a pretty bad overall car!

Yeah, I saw that when I was checking the cables coming through. I’d rather not have to choose between losing wiper or de-mist just to remove the hatch function, bloody thing!

[largespiced]

Burrito said:

Yeah, I saw that when I was checking the cables coming through. I’d rather not have to choose between losing wiper or de-mist just to remove the hatch function, bloody thing!

I dare say its a trip to a auto spark maybe. I lost faith in mine and got rid, but I did try and tackle this job first as I had a fog light out warning constantly. This was before the boot starting popping open. Much worse if it happens at 40 and you have the windows down!

You access the cables via the speakers in the boot. Sounds easy until you are laid on your back in the pissing rain and its not as easy as the youtube videos make out!

[bigdom]

It's the cable running through the two hinges, which is likely to be the issue.

It's not difficult per se, I have a pdf more specific to the aerial repair, although same procedure to get to the cables. I'd you'd like a cope of the pdf, PM me and I'll email it over.

Edited by bigdom on Thursday 14th February 11:14

[Burrito]

bigdom said:

It's the cable running through the two hinges, which is likely to be the issue.

It's not difficult per se, I have a pdf more specific to the aerial repair, although same procedure to get to the cables. I'd you'd like a cope of the pdf, PM me and I'll email it over.

Edited by bigdom on Thursday 14th February 11:14

These ones!?

Already been through and repaired.

I’m going to try one more time at the weekend and see what I can do.

[Senolmurat]

Hi, I just saw your message below. I have the same issue with the glass door popping, sometimes not opening when it should. Sometimes the metal door popping, or not opening when it should.So I have every st combination that can go wrong with those two doors

I'd really appreciate it if you could send me the pdf you talked about, hopefully with some info about what cable does what, and how far I need to dig when I try to repair them.

Thanks a lot in advance. This has been bugging me for a very long time. It's time to pull some DIY muscles.

bigdom said:

It's the cable running through the two hinges, which is likely to be the issue.

It's not difficult per se, I have a pdf more specific to the aerial repair, although same procedure to get to the cables. I'd you'd like a cope of the pdf, PM me and I'll email it over.

Edited by bigdom on Thursday 14th February 11:14

[Burrito]

I’ve just had a quick look but no longer have the pdf from Bigdom, hopefully he’ll pick this up.

Just to update where I finished with this. I could never find the bad earth (which I think is the cause) so ended up removing the power to the motor in the switch mechanism to permanently stop the function of the glass hatch.

Then realised one of the rear springs had broken, and the rear shocks were shot; so fixed and sold.

Good luck!

[michaelfoz]

Having the same issues atm! Currently in the middle of replacing the wires where they pass through from the cab to the boot.

If you’ve got basic tools/knowledge then this appears to be very doable.
I’ve been dicking about with cars in my spare time for years and I’m about 2 hours deep. All the loom is marked and cut. Now it’s just time to solder in new wires. Fun and games.

[beambeam1]

Burrito said:

These ones!?

Already been through and repaired.

I’m going to try one more time at the weekend and see what I can do.

When I had this issue I recall it was actually some wiring on the left/passenger side that was broken. Same symptoms as you, driving along and it would pop open.

[beambeam1]

That's how bad mine were on the driver's side. I have a dog so the boot was used a lot.

The left was only a few but further down the sleeve so I had to cut a 30cm length of wire to repair and leave some slack.

[michaelfoz]

beambeam1 said:

That's how bad mine were on the driver's side. I have a dog so the boot was used a lot.

The left was only a few but further down the sleeve so I had to cut a 30cm length of wire to repair and leave some slack.

Oh wow! I’ve only found minor cuts in the insulation but I’m just going to replace the sections that pass through to the boot. Saves all the faffing about.

I reckon I’ll probably get a new window switch ordered up as well and just try to eliminate that factor