Body/Trim: Rear Tailgate Handle repair - Guide

[BestGear]

Originally Posted by indiebands

Thanks, David. Out of curiosity, I assume that the parking assist camera would present another obstacle. I haven't even taken delivery of the car, much less had any sticky tailgate problems, but was just wondering. Thanks in advance.

Hi - yes, but I am sure there is a connector for the OEM camera at the tailgate so easy to unplug...

Great to see the other guys getting stuck in... such an annoying problem and and easy fix...

David

[siggi757]

Just wanted to say thanks for the write up. Very helpful.

Attempted this job today and it went quite well until I tried to punch out the pin. It was as it had expanded with all the rust. I was unable to budge it with out risking damaging the surroundings. Settled with freeing it up as best I could and spraying it with various rust removing and rust inhibiting chemicals. Had a bit of a trouble with the rubber seal around the handle unit. Would have been nice to have a replacement seal.

Cheers

[BestGear]

Originally Posted by siggi757

Just wanted to say thanks for the write up. Very helpful.

Attempted this job today and it went quite well until I tried to punch out the pin. It was as it had expanded with all the rust. I was unable to budge it with out risking damaging the surroundings.
Cheers

Hi

The pin was tight on mine - I applied loads of WD40 and left it for 10mins, then held the unit vertically on top of the vice and then drove the pin out with a drift.

It was tight - from as you say the swelling of the rust - but it did come out with no damage.

Given that you have had it in bits already, another go when its warmer will take you half the time!

David

[RoyMacDonald]

Would a moderator kindly make this a sticky please?

[Arianne]

Finally got around to doing this job..........

First & foremost, big, big thank you to Best Gear. Truly spot-on instructions and great photos.

Ordered the stainless steel rod from eBay as per instructions. £1.50 for item and £1.50 postage. Arrived this morning. No probs.

The job was quite straightforward for the most part and would have taken me 60-90mins except for one hiccup......

Of the four nuts which hold the rear lamp & handle assembly in place, one of them (the last one,would you believe it) had been cross threaded and wouldn't budge. Tried all the usual stuff such as WD40 but to no avail. The nut and the bolt were just spinning around together because the base of the bolt had worked free of its plastic moulding in the housing.

Anyway, finally managed to get the assembly free of the tailgate, punched the corroded pin out, cleaned it all up (including the spring) and reassembled with the shiny new stainless steel 304 grade pin. Lashings of white lithium grease on the spring for good measure.

Result - as good as new!

Couple of points worth noting:

• I removed the three bolts which hold the rear wiper motor in place as it made access to the two centre nuts much easier;
• I found the removal of the trim around the inside of the rear tailgate relatively easy with none of the poppers breaking and no near misses;
• Removing the cable from the lock mechansim was easier if you slacken the cable by wiggling the handle at the same time. It wasn't too difficult;
• You need torx screwdriver for some of the screws. I think they were size 25 (or maybe 20, can't be sure now), and
• The little shroud around the cable pivot holder thingy - don't forget to get this reassembled BEFORE remounting and securing the handle/ lamp holder into the tailgate. I didn't and needed to take the thing off again as it's too fiddly to do it after the unit has been refitted into the bodywork.

So, once again - thanks guys. Much appreciated. Arianne.

[chb]

Just had a look at my MY 2005 car, the bar is really badly corroded. I can see this job going on the list soon! Thanks for the excellent write up.

[Coconut]

My 2008 model XC90 is just coming to the end of the 3 year warranty period,
and just last week the tailgate handle started to stick.

Had a quick look up undernath and confirmed that the pivot pin ( or whatever it is called ) was all rusty and obviously the casue of the mechanism sticking,
so booked it in with the official Volvo dealer and explained about this known fault, stating that I expected the mechanism to be replaced under warranty.

Got the car back the next day and all they have done is "cleaned and lubricated" the part, which has freed it up.
( Looking up underneath - the visible part of the pin still looks the same {rusty} so I suspect it has simply been treated to a helping of WD40 or similar ).

I questioned this asking how long their "repair" would be warranted for,
and they explained it would only be warranted to the end of the manufacturers warranty - i.e. a few days !

Not at all happy with this answer I asked why the mechanism had not been replaced and was told that Volvo
would not authorise replacement as the part had not "failed", it just needed lubricating.

The chap did say that if it was a piece of visible external trim, or body panel, or even a wheel that was corroded,
they would replace it - which I found strange because a bit of corrosion on an allow wheel
doesn't stop the wheel from turning, whereas the corrosion on my pivot had stopped the thing from working !

Of course anyone with half an ounce of common sense or the tiniest bit of engineering knowledge will know
that a rusty part "cleaned and lubricated" will soon go rusty again, so to my mind this is not a repair,
just a temporary measure to get me "back on the road", and allow my warranty to expire,
after which I will have to pay for the next "clean & lubricate" or buy a new mechanism myself, or do the stainless steel pin replacement myself :-(

I have raised the issue with Volvo Customer Services, but in the meantime....
has anyone had one of these tailgate handle / locks replaced under warranty due to rusting of the pivot pin,
and does anyone know if there has been a modification to prevent it happening in the future ?

Thanks,

[madnurse]

Mine has been 'sticking' for some time, never thought much of it (just another quirk of the car?) after reading this thread I have found that mine is really rusty under there!

1) I have well lubricated the part in WD40 equivalent from outside, lots of rusty fluid leaked back!

2) Will order parts and replace pin myself in near future.

3) Big Thanks

[BestGear]

Originally Posted by Coconut

My 2008 model XC90 is just coming to the end of the 3 year warranty period,
and just last week the tailgate handle started to stick.

I would remind them that the cause of it sticking is down to the poor quality of the zinc passivation that was applied to the part.... its not a standard part requiring lubrication.

If it were, it would be listed in the service schedule.

"not fit for purpose" would spring to mind with that component....

David

[RoyMacDonald]

Originally Posted by BestGear

I would remind them that the cause of it sticking is down to the poor quality of the zinc passivation that was applied to the part.... its not a standard part requiring lubrication.

If it were, it would be listed in the service schedule.

"not fit for purpose" would spring to mind with that component....

David

The V70 and XC70 have a tight fitting cover inside the taigate handle that protects the mechanism. Try and look at the pin on one of those cars and you won't be able to see it. Should have been fitted to the XC90 as well!