Tailgate and support struts - removal, refitting and adjustment

Bodywork and fittings / Tailgate and support struts - removal, refitting and adjustment

Removal
Tailgate
1 Disconnect the battery negative terminal.

Open up the tailgate.

2 Remove the inner trim panel by extracting the retaining clips first; use a wide blade screwdriver inserted beneath each retaining clip position in turn (see illustration).

16.2 Removing the tailgate inner trim panel and clips

3 Disconnect the wiring connectors situated behind the trim panel and disconnect the washer hose. Also disconnect the wiring connectors from the heated rear screen terminals and free the wiring grommets from the tailgate.

4 Tie a piece of string to each end of the wiring then, noting the correct routing of the wiring harness, release the harness rubber grommets from the tailgate and withdraw the wiring. When the end of the wiring appears, untie the string and leave it in position in the tailgate; it can then be used on refitting to draw the wiring into position. Similarly remove the washer tubing.

5 Using a marker pen, draw around the outline of each hinge marking its correct position on the tailgate (see illustration).

16.5 Tailgate hinge

6 Have an assistant support the tailgate, then using a small flat-bladed screwdriver raise the spring clips and pull the support struts off their balljoint mountings on the tailgate (see illustration). Slacken and remove the bolts securing the hinges to the tailgate and remove the tailgate from the vehicle. Where necessary, recover the gaskets fitted between the hinge and tailgate.

16.6 Prise out the spring clips before removing the support struts from their balljoint mountings

7 Inspect the hinges for signs of wear or damage and renew if necessary. The hinges are secured to the vehicle by bolts which can be accessed once the headlining has been freed from the trim strip and peeled back. On refitting ensure that the hinge gasket is in good condition and secure the hinge in position.

Support strut
8 Support the tailgate in the open position, using a stout piece of wood, or with the help of an assistant.

9 Using a small flat-bladed screwdriver raise the spring clip, and pull the support strut off its balljoint mounting on the tailgate. Note on Coupe models the upper mounting is of pin type and the strut is removed by sliding off the pin; recover the washers and spacers noting their positions. Raise the second retaining clip then detach the strut from the balljoint on the body and remove it from the vehicle.

Refitting
Tailgate
10 Refitting is the reverse of removal, aligning the hinges with the marks made before removal.

11 On completion, close the tailgate and check its alignment with the surrounding panels. If necessary slight adjustment can be made by slackening the retaining bolts and repositioning the tailgate on its hinges. If necessary, adjust the tailgate rubber buffers by screwing them in or out.

Support struts
12 Refitting is a reverse of the removal procedure, ensuring that the strut is securely retained by its retaining clips.