Member Since: 11 Aug 2017
Location: Helsinki
Posts: 6694
Upper tailgate handle removal
I was going to install the front runner ladder I recently purchased but the upper tailgate handle disagreed with me.
I got two of the four torx bolts out easily after a day’s soak in CRC but the two others (pictured) just turn. I did search the forums and it seems like the bolt receptacles in the plastic handle get lose.
Is it possible to access the other side of the bolts somehow by removing the interior trim on the upper tailgate? Any other tips on how to remove these? Using a Dremel came to mind but surely there are less destructive ways...?
Click image to enlarge
7th Sep 2019 12:13 pm
Ceekay
Member Since: 17 May 2009
Location: Bury
Posts: 2084
i think i remember having to drill one of these out on my old D3 D4 HSE Lux MY16 Club Waitomo
D3 HSE MY06 missing her still…
7th Sep 2019 12:15 pm
kajtzu
Member Since: 11 Aug 2017
Location: Helsinki
Posts: 6694
Sounds about as destructive as the dremel
So a vanadium drill bit?
(I do have new bolts so destroying the old ones isn’t really a problem)
7th Sep 2019 12:20 pm
eightfoot
Member Since: 12 Apr 2015
Location: sunny essex
Posts: 796
you don't need to drill them the ones that are spinning just prise the handle off of them leaving the bolt and insert on the tailgate then you can use grippers on the insert to hold then undo the bolt,after that just glue the inserts back in with some epoxy glueplease excuse any grammer/punctuation mistakes,i'm thick,thankyou
current vehicles 2005 d3 2013 d4
7th Sep 2019 4:06 pm
kajtzu
Member Since: 11 Aug 2017
Location: Helsinki
Posts: 6694
Eightfoot,
Do you mean I should first remove the interior trim (1 screw, the rest with clips), remove the three other bolts/screws (the ones behind the trim) and then just wiggle the whole plastic handle module away from the tailgate?
I thought these four bolts went through the handle but it sounds based on your description that they’re not.
Thanks in advance.
7th Sep 2019 6:25 pm
eightfoot
Member Since: 12 Apr 2015
Location: sunny essex
Posts: 796
yep just wiggle it off gently so not to damage anything if you look you will also see 2 long plastic lugs (looking thru the inside tailgate) push on them as well
all the cars I have owned I had to do the same just go easy and it will come off especially if the inserts are just spinning in the plastic when your trying to undo the bolts
ps interior trim has to come off as there is bolts and wires inside there (it just pulls off after you remove the single Philips screw that's inside the pull down handle on the inside trim)please excuse any grammer/punctuation mistakes,i'm thick,thankyou
current vehicles 2005 d3 2013 d4
Last edited by eightfoot on 7th Sep 2019 6:53 pm. Edited 1 time in total
7th Sep 2019 6:50 pm
Hot Tub
Member Since: 15 Aug 2017
Location: Milton Keynes
Posts: 1071
If memory serves me right don't you also have to remove three 10mm nuts Welsh Collie Chauffeur Service To Barney & Rooney.
7th Sep 2019 6:51 pm
eightfoot
Member Since: 12 Apr 2015
Location: sunny essex
Posts: 796
^^^ inside the trimplease excuse any grammer/punctuation mistakes,i'm thick,thankyou
current vehicles 2005 d3 2013 d4
7th Sep 2019 6:54 pm
kajtzu
Member Since: 11 Aug 2017
Location: Helsinki
Posts: 6694
Drilled the two screws that just didn’t just want to come out. Violence solves most problems, right?
As the screw and the receptacle were metal, they had “interacted” with each other during the last 14 years. The easiest way ended up sawing through the removed receptacle to remove rest of the thoroughly rusted screw. Glued the receptacle back into the tailgate handle with some two-component epoxy....
Click image to enlarge
Click image to enlarge
End result is what counts, right, so:
Click image to enlarge
Click image to enlarge
As I didn’t have the z-clamp - and didn’t feel like figuring out how to manufacture one - for the front runner ladder I used some more of the epoxy glue to glue the top of it to the tailgate. Let’s hope it stays there for the rest of the vehicle’s lifetime. FWIW, front runner’s support never even bothered responding to my polite inquiry.
All in all, for the money spent, a pretty good result.
Need to get new sticker since the existing one is now hidden and we can’t have that, can we? 8)
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others (pictured) just turn. I did search the forums and it seems like the bolt receptacles in the plastic handle get lose.
FWIW, front runner’s support never even bothered responding to my polite inquiry.
