Just what I'm looking for; my boot is currently locked shut, can I do all this from inside without some other method of opening the boot? I noted the comment about don't close the boot and as mine is ...........

Hi Bestgear

Many thanks for taking time and effort to post this comprehensive guide.

As they say a picture paints a thousand words and all the pictures along with the words of explanation makes me feel far more confident of undertaking the job, when the cold weather goes away that is.

Cheers Noel

Hi Bestgear

Many thanks for taking time and effort to post this comprehensive guide.

Did mine today. Would have finished it in 40 minutes, if it wasn't for one of the 4 bolts wouldn't budge, and had to resort to 1.5 hours of drilling it out, as its in such a position that its difficult to get 2 tools in the to hold each part.

Anyway, job done, and now functions perfectly. Thanks for the details explanation as i wouldn't have had the balls to pull it apart blind.

cheers

Stu

Hi Noel and Stu...

Glad the guide helped.... at least you wont need to do the job a second time!

David

I couldn't get the pin out today either, it was near the point when I would have damaged it beyond repair as i was punching it as hard as I dare, the pin was starting to disappear inside at the side I was punching, "great, it's going" I thought, but it wasn't coming out the other side so I can only assume it was beginning to bend.
I wonder if I will try one from a breaker to see if I can get the pin out of that and fit the stainless which I have ready cut, does anyone know a good Volvo parts supplier or can point me to a site where I can search part numbers as I could be doing with a new gasket for the boot handle surround plus a couple of new gaskets for the number plate lights too while I'm at it.
Thanks again to David for the informative guide as it made taking everyhting out & reassembling very easy to follow.
Cheers
Ally

Thanks for the thanks - glad it was of use to you.

David

Tailgate will not open
 

Is there any way of opening the tailgate as there is only access via remote. Can it be done manually?

I dont believe there is, without opening up the tailgate trim and manually tweeking....

David

Hi David

Bought the 4 mm rod some time ago and now the weather is warmer I decided to have a go. Once again many thanks for the write up and the excellent pictures.

I think I could have done the job without them, but your guidance made the job far easier, I felt far more confident and managed to avoid all the pitfalls.

Like others I found your comment "The hinge pin can now be simply drifted out" a tad optimistic. Soaking all the parts in WD40 for 30 mins helped, I used the time to work out a way of holding the plate securely in a vice, without damaging it. After a while, using a 3mm rod as a drift, and some 'gentle' tapping/persuasion it started moving.

Once sufficient rod was exposed, I gripped it in the vice and using a twisting motion managed to extract it.

One thing I would add is the cause is the poorly fitted handle plate, even though it has a recessed neoprene foam seal, inspection revealed that it was not in contact with the tail gate all the way round. It was also saturated with water and when pressed you could actually squeeze the water out.

I dried it best I could applied a bead of black sealant all the way round the seal, tightened the 4 nuts and then cleaned off the excess. I appreciate that the stainless steel is unlikely to rust, but one of the 4 fixed bolts, like yours, already had a film of rust on it and I could imaging left to their own devices they could all become difficult to remove. I also applied a coat of copper-slip grease to the rod and all the threads before reassembly. A stick in time etc ....

So job done and a big thank you to you.

Cheers Noel

My Weather station is at :http://www.wunderground.com/weathers...ID=IENGLAND236

Hi Noel

Glad it all worked out - as you say not a difficult job really... just one on the list to scratch off.

I did find the hinge pin just drifted out - it was tight but it had to move! Its surprising the amount it "swells" when its rusty - perhaps yours was more rusty than mine, hence tighter.

I just noticed that it was back in October I did the fix - and the handle today is as fresh today (approx 18 months later) as it was when "upgraded".

Have fun.

David