In reply to Richard Alderton:
Just checked a DMM and a Troll harness, end of belt is secured on both. Admittedly just sewn onto a sliding elastic belt loop, but ends of belt doubled over and sewn together to be too thick to pull through buckle. Looks like it would be a real pig to rethread if you did manage to pull it through. You may get better answers if you said which make and model you're dealing with.
Just looked again at your post
> Anyone else had something similar? I'll get in touch with Acme Climbing Products Inc and see what they think.
Sounds like an idea, you can probably find an instruction manual online somewhere.
PS At 5yrs old they'll probably tell you to replace it
Post edited at 16:30