Member Since: 25 Jan 2019
Location: hampshire
Posts: 29
D4/D3 Upper Tailgate Actuator -replacement with £12Ford Part
Edit 2 - longevity update
============
The fix below lasted just over 3 years and 40K miles of family use - this weekend I got the slow actuator symptom again so ordered another and will be fitting this week.
For the sake of around £10 to fix again I can live with that!
Interestingly, the outside tailgate switch stopped working around 6 months ago - and looking at posts on that topic, I'm thinking it may be an early warning of an actuator on it's way out.
============
Edit: Solution confirmed & written up
Hi all (mods - don't know how to cross post but this is relevant for D3s also - possibly wiki too)
Upper tailgate actuator failed.
Short version:
Hypothesis: Is there a cheaper and less wasteful way of replacing the actuator?
So... I'm attempting to try using an alternatively sourced actuator module (without the metal plate and plastic cover) after hunting down codes from the module itself (printed on mine was "FoMoCo P545K").
Answer: Yes there is. Search for ford part no. 1481081.
Longer version:
Situation:
Had the usual 'weak' actuator symptoms (intermittent ability to open upper tailgate) and, like many, I lubed it up, ignored it - and found myself unable to open it at all.
Confirmed microswitch on tailgate handle still working + faint whirring noise of actuator attempting to release the catch.
Solution:
1. Followed the many good guides to 'fight' my way into the tailgate from the inside (I'm 6'4 so glad it wasn't the boot of a Fiesta!). Hands bruised, air blue, but managed to release it.
2. Disassembled tailgate as necessary, and extracted the offending actuator assembly.
3. Separated the actual actuator module from its metal backing plate (keeping screws safe)
4. Googled the numbers & codes & pics on it to see if i could find similar
Turns out it's in fairly common use (mainly on Fords - part no. 1481081) so studied the options available to get as close a match as I could find - including the electrical connector (which seems to be common).
7. Separate new actuator from metal ford part assembly (2 screws)
8. Slide off metal assembly from top of actuator
8.5 Test them both for fun - clearly the old one is shot.
OLD
NEW
9. Pop on LR latch cable connector
10. Screw new actuator onto LR backplate
Click image to enlarge
11. Reinstall actuator assembly into tailgate
Done. £12 all in, bar some duct tape to repair the foam barrier cuts.
Extremely satisfying. Hope it's useful.
A
PS> Part 2 may be a tear down of the defunct actuator to see what the ACTUAL problem was. But that's for a rainy day.
Last edited by arb on 4th Jun 2023 10:39 pm. Edited 10 times in total
6th Apr 2020 6:05 pm
pwheeldon
Member Since: 14 Jan 2020
Location: West Yorks
Posts: 1505
Good call. I know on the Aston Martin owners club forum they have a spreadsheet of alternative Ford and Jaguar parts that fit Astons, do we have anything like that? There must be loads of Ford and Jag parts that fit these cars.Discovery 4 GS 2009 Auto Stornoway Grey
Discovery 3 s 2005 Auto Bonatti Grey Gone
Discovery 3 SE 2005 Manual Zambezi Silver Gone
Range Rover Sport HSE 2006 Black
Aston Martin DB7 VV
Even applies to oils ... cheapest local place when I needed 5w30 c1 in a rush was Quickco, the Ford parts supplier in Trafford Park..
Dean
====================================
2011 D4 XS - OBD port protection, RLD spare wheel protector, All LED interiors lights, Timed Climate enabled, iiD tool paired.
2011 D4 Landmark - Stolen from same dealer before I paid for it
2011 D4 GS - Stolen whilst at dealer ... All LED interiors lights, DRLs, Spare Wheel protector.
1996 300Tdi - Eaten by tin worms
7th Apr 2020 5:48 am
arb
Member Since: 25 Jan 2019
Location: hampshire
Posts: 29
Project now edited and written up - success!
Enjoy.
9th Apr 2020 8:38 pm
M3bobby
Member Since: 21 May 2018
Location: Sleaford, LINCS.
Posts: 857
My car has Ford (FoMoCo), BMW and Volvo parts.012MY RRS 5.0 Supercharged Autobiography (Current)
Mods:
TPMS (Complete but got an issue)
Genuine LR DRLs (Complete)
Remote Boot close from key fob (Complete)
2016 Discovery 4 Mirrors AKA RRS2 (Complete)
2014 L405 Surround Camera retro fit (Now 2016 L319)
2013 RRS Dual View Screen fit (Complete)
2016 LR4 RSE (Complete)
2014 LR4 Homelink (Complete)
2016 FFRR Electrochromatic Wing Mirror Glass (Complete)
9th Apr 2020 10:12 pm
NC500
Member Since: 18 Sep 2017
Location: On the NC500
Posts: 544
Excellent, thank you 🙏🏻
10th Apr 2020 6:16 am
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 511
Actuator
Good initiative there. I did mine for a small fortune with Land Rover parts. Next time 👏Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
10th Apr 2020 6:31 am
M3bobby
Member Since: 21 May 2018
Location: Sleaford, LINCS.
Posts: 857
A Sticky with alternatives is a good idea.012MY RRS 5.0 Supercharged Autobiography (Current)
Mods:
TPMS (Complete but got an issue)
Genuine LR DRLs (Complete)
Remote Boot close from key fob (Complete)
2016 Discovery 4 Mirrors AKA RRS2 (Complete)
2014 L405 Surround Camera retro fit (Now 2016 L319)
2013 RRS Dual View Screen fit (Complete)
2016 LR4 RSE (Complete)
2014 LR4 Homelink (Complete)
2016 FFRR Electrochromatic Wing Mirror Glass (Complete)
10th Apr 2020 9:36 am
Motty
Member Since: 18 Nov 2018
Location: Atherstone Warwickshire
Posts: 108
This is a great read ordered mind off email
11th Apr 2020 7:58 pm
arb
Member Since: 25 Jan 2019
Location: hampshire
Posts: 29
Thanks for the positive fb.
Had a few pm questions re compatibility of this fix:
This actuator fix would work for all models that use part number FUG500010 for their actuator, as it replaces the actual actuator piece inside the assembly.
So in practical terms, that's Disco 3 and 4 2005-2017 inclusive.
Enjoy your fix / hack!
14th May 2020 5:46 pm
Adiver
Member Since: 18 Jan 2006
Location: Rutland
Posts: 495
Upper tailgate motor
Excellent! I followed these instructions, bought the part off eBay for £14.99. It was delivered three days later and I fitted it no problem! I had to file the plastic end down a bit to fit the cable connector as it was about 3mm longer than the original.
All works perfectly again. Saved a small fortune!
Thanks for the write up
To clarify, this works on a 2012 MY D4 with keyless entry
JonD4 SDV6 HSE
18th May 2020 10:22 am
Pete Hancock
Member Since: 11 Oct 2018
Location: Cornwall
Posts: 94
Just a quick comment on this......
Wonderful thread, well done, ....but....
Please, buyer beware...!
GENUINE Ford part No. 1481081 is about £95.00
Most of the ones listed on e-bay at about £12.00
If you scroll down through posts to seller details, usually some hint of Chinese connection ?
Is this a case of "you get what you pay for" ?
Has anyone fitted one of the copies and had it last as long as genuine part ?
Or is it like buying part from a scrapper ? I had Primera years ago, window winder died, bought replacement from scrap, lasted about a month and died same as original, did same again, same result.
Decided to buy new OEM part, about twice the price as 2nd hand, fit once and forget.
Lesson learned !!! Including time and damage to fingers etc. would have been a lot cheaper.!
18th May 2020 11:52 am
arb
Member Since: 25 Jan 2019
Location: hampshire
Posts: 29
Thanks Pete - I hadn't meant for the original post to encourage people to buy the OEM ford part. That would defeat the spirit of the hack.
For my part, I ordered and used the £12.99 one behind the ebay link in the writeup (FYI arrived in a couple of days and still working solidly after 2 months - of course will report back if it packs in).
This project was always only ever meant to be a hack / workaround - using a cheaper / less wasteful solution than the original LR OEM part.
As an aside, I'd imagine that even the original ford part would be manufactured in places all around the world, - country of origin alone not always the best predictor of quality or longevity.
Best wishes
A
18th May 2020 3:23 pm
Pete Hancock
Member Since: 11 Oct 2018
Location: Cornwall
Posts: 94
Hi arb,
Only trying to make the point "buyer beware", as SELLER on a lot of e-bay items, although listed as "Aberdeen" or wherever, often looks dubious when you dig deeper.
I have been looking for items in the past, same item description, different seller / location, but when you scroll down to find details, were the same name and business address,often London and usually Chinese name. Classic "Drop-box / P.O. box tactic.
Only started checking this after not receiving an item, (luckily only a few £ !) and not getting any reply from seller, only to get a message from same asking me why I would not leave him positive feedback !!
I agree, lots of parts are manufactured overseas for OEM supply line, but lots of cowboy imitations claiming to be "OEM" as well, I personally would rather pay a bit more to a LR dealer, than risk my pride and joy mysteriously catching fire due to inferior parts.
Fully agree with sourcing IDENTICAL parts from other marques if cheaper.
19th May 2020 4:12 pm
Kitetraveller
Member Since: 31 Dec 2018
Location: Brittany
Posts: 97
Had the same issue on Monday afternoon, part ordered via Amazon arrived and fitted this afternoon.
All tested and working well. I did install a paracord pull release as well.
Many thanks for the time and effort to put together the write up, greatly appreciated!
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... All LED interiors lights, DRLs, Spare Wheel protector.
Good initiative there. I did mine for a small fortune with Land Rover parts. Next time 👏
