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Discussion Starter #1
there are two types of tailgate and hinges.
91-96 and 96-03

if you fit an early tailgate to a late van it might not open fully
the mounts for the struts are in different places on the door

early door


late door


see the early door has the fixing higher up

early hinge


later hinge


here's the door i got.




i took the seal off the window and replaced it after it was painted


first thing you need to do is disconnect the wires from behind the rear light clusters

then undo the hinges with a 6mm allen key.
some of them came out easy.
some had to be removed using a bolt remover.



take all the catches off



you need to use one of the plates for the new centre catch.
i just whacked it loose and moved it over.
you need to use the bolts that come with the center catch as they are slighlty longer than the ones off the twin doors.




you need to drill some hole for the hinges




you now need a mate to help lift the new tailgate into position.
use a prop to keep it open while you tighten the nuts on the hinges and fit the struts
 

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Discussion Starter #2 (Edited)
fitting the struts is quite easy. there are two creases in the metal work which they fit between.
mark and drill the holes. and use rivnuts for fixing.





fitting the side catches can be done too. just lash some rivnuts in and bolts them on




it should now stay open on its own!

and shut


the one on the right is the tailgate lock. it's well bigger than the barn door one? :dunno
you need to take the flat pins out of the barrel. pull them out if you have thin fingers.
you may need to push them through with a thin electrical screw driver.
take the ones out of the long lock. 5 on one side 2 on the other.
you only need to be concerned about the order they come out of the small lock.
and that they go in the long lock the same way. put some copper slip in there too.




there it is.


thanks to Mike and Bob from Bolton for the door.
Mike CMC for getting it painted suplying the window rubber and rivnutting the bits for me.
also for showing me how to do it in the first place!
and Tallpaul for coming al the way from Rainhill just to tighten up 4 nuts
 

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great thread :)

i just bought a tailgate from a m reg t4 , but it has the the later flat hinges and lower strut point on tailgate ?

Will this fit my 2000 t4 van ok ?

it apears to be a late tailgate on an early van that i got :*
 

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See my build thread mate if you want. You need M6 rivnuts. Plus you need to replace the bolts holding the striker plates at the bottom with some that are about 10-20mm longer.
 

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Discussion Starter #10
sorry boyos.....spent too much time int pub

M6 rivnuts is correct sir T:
 

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Is it a simple swap to change my lock from the barn door and put it into the tailgate? Are the components the same and will my central locking swap over too?
 

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i am t4lwb steve
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wrong length i believe so you need to use the tumblers from the barn lock for the tail gate one
only quoting the about thread
steve
 

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Discussion Starter #16
Is it a simple swap to change my lock from the barn door and put it into the tailgate? Are the components the same and will my central locking swap over too?
You need both locks. Tailgate lock is different.
You need to swap the bits over.
But make sure they go back in the right order.

Check the pics with the teeth.
(my mate's a dental tech)
 

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thanks for this write up will def help me.

for info i struggled to get hold of the slam guides and two brackets for the gas struts however these are available from VW Van Centre's around a tenner each.

Whats the best method/tool for removing the allen key bolts, if stuck or rounded?
 
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