Body/Trim: - Rear Tailgate Handle repair - Guide - Page 7

BestGear · Dec 9th, 2013, 20:27

Quote:

Originally Posted by Mark mc

So frustrating - couldn't get enough force onto the old pin as couldn't remove whole assembly.
Annoyed!!

Really annoying as you say.

Plan B, if you cant get a grip on any other part of the thread is to force it off and perhaps refit with some hot melt glue or even silicon....

Plan C, if it has started to come off, try wedging a forked trim tool between body and nut to try and keep it tight..and undo the nut...may not be possible....

Post a photo and we will see what we can do...

David

uu26 · Dec 10th, 2013, 22:00

Hi all,

So I've had my 2004 xc90 for 9 months, just been through the ignition sticking and dremeling out the relocker pin & 2 days later the handle that has been "sticking" (I've always had to push the handle back to then pull the boot open) will not engage the boot at all!

Want to attempt the repair and I'm guessing either the rod or spring has gone, can I get to the cable to release with the boot closed? And if its the spring that's gone, am I looking at a new assembly?

Cheers

BestGear · Dec 10th, 2013, 22:31

Quote:

Originally Posted by uu26

Hi all,

Want to attempt the repair and I'm guessing either the rod or spring has gone, can I get to the cable to release with the boot closed? And if its the spring that's gone, am I looking at a new assembly?

Cheers

Can you not open it by resetting (push back) the handle as usual?

You can remove the boot trim without opening it, but must easier with the tailgate open, obviously.

You can see the cable and where it attaches to the handle in one of my pictures above.

The spring never usually "goes" its the friction caused by the build up of rust that makes the hinge so tight, and also why wd40 sorts it for a week or so...

David

uu26 · Dec 10th, 2013, 22:40

Thanks for the quick reply, tried several times to reset but it won't and the handle is just dead, I'll try and remove everything from the boot & have a go getting to the cable to release from inside, should be fun!

Thanks for the feedback on the spring, just wondered why I can't reset the handle any more & thought that might be the culprit!

Thanks again..

Shadeyman · Jan 2nd, 2014, 14:16

I agree the cable tie method is a quick fix its certainly not ideal.

My car had this cable tie method done to it. The cable tie interferes with how the cable twists in clip on the rear of the handle. The result is a bent cable that eventually refuses to push back into its sleeve preventing the boot opening.

My advice is source and fit a second-hand handle.

hibutts · Mar 7th, 2014, 22:24

Just carried out the repair. Works a dream.
Thanks for posing such a comprehensive fix.

xBeast · Mar 17th, 2014, 00:58

Meddler 34 - not able to view picture of Springs that you attached to this post, could you forward them to me or repost and notify.

Thanks
JFF

Quote:

Originally Posted by meddler34

Yesterday decided to sort the handle, after finding spring snapped other month. Round bar 4mm B&Q £1.98, took old spring and bent into what I thought looked like it's proper shape. Got lucky first time, the arms (as seen in photo) are parrallel to each other. All put back together, now sorted.

http://www.volvoforums.org.uk/showth...te+lock&page=4 : Attached Thumbnails

owenfackrell · Mar 17th, 2014, 08:36

Did this to mine at the weekend. I found it easier to get the cable out by removing the 3 bolts that hold the catch in and then lifting it up and relasing the cable outer. This lines up the cable to come straight out of the holder. I will have to replace my number plate lights at some point as they have be come so brittle that the tabs have snapped clean off.

NeedTeddy · May 1st, 2014, 02:49

Thanks for the great write-up. I am in the states and we don't experience a lot of Corrosion where I am at but your guide helped me removed the rear hatch panel to install a backup camera. If anyone wants any details, please send me a PM.

MisterWooley · Jul 28th, 2014, 20:24

Been wanting to do this mod for a while as my tailgate handle has been driving me mad. Thanks to the excellent post got it all to bits easily. Had the SS replacement bit all ready. Guess what. Spring broke during reassembly. It had rotted and the little tang broken off. Half of the spring was almost gone!!!

Really hacked off. Don't have time to find replacement spring so off to Volvo tomorrow with chequebook

Dec 10th, 2013, 22:00	#62
uu26 New Member Last Online: Dec 12th, 2013 15:15 Join Date: Jun 2013 Location: Kingston upon Thames	Boot locked shut Hi all, So I've had my 2004 xc90 for 9 months, just been through the ignition sticking and dremeling out the relocker pin & 2 days later the handle that has been "sticking" (I've always had to push the handle back to then pull the boot open) will not engage the boot at all! Want to attempt the repair and I'm guessing either the rod or spring has gone, can I get to the cable to release with the boot closed? And if its the spring that's gone, am I looking at a new assembly? Cheers

Dec 10th, 2013, 22:40	#64
uu26 New Member Last Online: Dec 12th, 2013 15:15 Join Date: Jun 2013 Location: Kingston upon Thames	Thanks for the quick reply, tried several times to reset but it won't and the handle is just dead, I'll try and remove everything from the boot & have a go getting to the cable to release from inside, should be fun! Thanks for the feedback on the spring, just wondered why I can't reset the handle any more & thought that might be the culprit! Thanks again..

Jan 2nd, 2014, 14:16	#65
Shadeyman VOC Member Last Online: May 28th, 2020 23:57 Join Date: Jun 2012 Location: Wolverhampton	I agree the cable tie method is a quick fix its certainly not ideal. My car had this cable tie method done to it. The cable tie interferes with how the cable twists in clip on the rear of the handle. The result is a bent cable that eventually refuses to push back into its sleeve preventing the boot opening. My advice is source and fit a second-hand handle.

Mar 7th, 2014, 22:24	#66
hibutts New Member Last Online: Jan 21st, 2024 00:19 Join Date: Sep 2007 Location: Hampshire	Just carried out the repair. Works a dream. Thanks for posing such a comprehensive fix.

Mar 17th, 2014, 08:36	#68
owenfackrell Premier Member Last Online: Feb 4th, 2024 19:04 Join Date: Dec 2009 Location: southampton	Did this to mine at the weekend. I found it easier to get the cable out by removing the 3 bolts that hold the catch in and then lifting it up and relasing the cable outer. This lines up the cable to come straight out of the holder. I will have to replace my number plate lights at some point as they have be come so brittle that the tabs have snapped clean off.

May 1st, 2014, 02:49	#69
NeedTeddy New Member Last Online: Jun 25th, 2014 17:27 Join Date: May 2014 Location: Los Angeles	Thanks for the great write-up. I am in the states and we don't experience a lot of Corrosion where I am at but your guide helped me removed the rear hatch panel to install a backup camera. If anyone wants any details, please send me a PM.

Jul 28th, 2014, 20:24	#70
MisterWooley Junior Member Last Online: Sep 12th, 2023 12:49 Join Date: Jan 2014 Location: Leicester	Been wanting to do this mod for a while as my tailgate handle has been driving me mad. Thanks to the excellent post got it all to bits easily. Had the SS replacement bit all ready. Guess what. Spring broke during reassembly. It had rotted and the little tang broken off. Half of the spring was almost gone!!! Really hacked off. Don't have time to find replacement spring so off to Volvo tomorrow with chequebook

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