Member Since: 10 Mar 2011
Location: Bolton
Posts: 44
Tailgate Catch Internal Release Cord
Hi
I learned on here last week that my tailgate actuator was probably failing, and that it is a bit of a nightmare to get the tailgate open if the actuator fails, or if the cable end connection in the actuator fails.
Yesterday I fitted a replacement actuator - £24 of ebay, quite a straightforward job. I'm thinking "how long will this cheap component last, what if it fails and l can't open my tailgate?". Anyway I thought of a very cheap easy solution, I've done it today, and it works.
I've included step by step photos to demonstrate what I've done....
Firstly, remove the 4 caps and screws on the lower tailgate section, then pull the plastic section upwards to release it. Ensure you don't lose the 4 metal clips inside the trim (1 at each screw point)...
Click image to enlarge
Click image to enlarge
Then, 13mm spanner - undo the tailgate lift cable each side, and carefully let the cable retract up into the car body. *undoing the bolt is easier because it prevents the cable end for disappearing into the recess...
* Also, support the lower tailgate when removing the support cables...
Click image to enlarge
Click image to enlarge
Click image to enlarge
Next, lift up to unclip the carpet panel trim...
Click image to enlarge
Click image to enlarge
The actuator is in the centre, unclip the electric connection RHS, feel for/press the clip on the plug to release the cable...
Then, loosen the 2 bolts from above. This allows the actuator to be slid out in the centre hole...
Click image to enlarge
Remove the 2 star screws and lift off the cover.
You can see the cable connected to the actuator. You can easily test it by connecting the electric connection and pressing the button on top tailgate, you will see the actuator pull the cable then release it...
Apparently, the faults with these actuators is they wear out and fail, also the cable end 'L' piece can snap or detach itself from the actuator.
*To make the cable end fitting more secure I added a small cable tie around the fitting.
Click image to enlarge
For my 'Quick Release' cord I used a length of picture cord - ie. low stretch nylon cord (ie. decent string).
I used a piece of electrical connect block as a clamp, however it could be tied in a double knot tbh...
The idea being that if the actuator failed, OR if the cable end disconnected, the cord can be pulled to release the tailgate...
I threaded the cord through the actuator casing and replaced the cover...
Click image to enlarge
Click image to enlarge
Click image to enlarge
I then fitted the actuator back in place, connected the electrics, I threaded the cord out through the trim at the RHS tailgate support cable point...
I reconnected the tailgate cables and the cord (string) was hanging loose...
Click image to enlarge
I then tested it, perfect!
Lastly, I tidied up the cord end. I put a black electric cable cover, but in the end I used gaffa tape to hold it down in case of emergency.
The main thing is it's easily accessible from inside the bootspace when the tailgate is closed...
Click image to enlarge
Click image to enlarge
I hope this is helpful, it didn't take long, in fact its taken much longer to photograph and type up this posting...Rob
There's a permanent latch mechanism available from PowerfulUK that could be used and fitted properly with an internal latch like a front door.2011 MY D4 HSE
Previously 2001 D2 TD5, 1996 D1 300Tdi, 1985 90 2.2 petrol.
Bikes! KTM, BMW, British, Classics and others.
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