Tailgate (Hatchback and Estate models) - removal and refitting
Note: On Hatchback models made before 1990 with an integral heated rear window/radio aerial, note that the radio aerial lead is routed through different openings to that of other models in the rear bodywork and the tailgate. If a new, later-specification tailgate is to be fitted to an earlier vehicle, a new opening must be made in the bodywork for the aerial lead. Ideally, this work should be carried out by a Ford dealer, who will have the necessary template available to ensure that the opening is positioned accurately.
Removal
1 Disconnect the battery negative lead.
2 Open the tailgate and prise out the trim panel using a wide-bladed screwdriver.
3 Disconnect the wiring from the heated rear window, rear wash/wipe, interior light, lock solenoid and “tailgate ajar” sensor, as applicable. Disconnect the washer fluid hose where applicable; be prepared for fluid spillage.
4 Release the wiring loom/hose grommet(s) taking care not to lose it/them, then tie string to the wiring loom(s)/hose, and pull the loom(s)/hose through the tailgate. Leave the string(s) in position in the tailgate to aid refitting of the loom(s)/hose.
5 Have an assistant support the tailgate, then disconnect the support struts by prising out the retaining clips. Do not remove the clips completely, just raise them by a maximum of 4.0 mm (0.16 in) and then pull the struts off their mountings (see illustration).
11.5 Prising out a tailgate strut retaining clip
6 Prise out the hinge fixing covers from the headlining, unscrew the hinge nuts and washers, and with the aid of the assistant, withdraw the tailgate from the vehicle (see illustration).
11.6 Tailgate hinge assembly - Hatchback and Estate models
Refitting
7 Refitting is a reversal of removal, but do not
fully tighten the hinge nuts until the tailgate is
positioned centrally in its aperture. If
necessary, adjust the position of the lock
striker so that it engages fully in the lock.
See also:
Inlet manifold - removal and refitting
SOHC models
Removal
1 Disconnect the battery negative lead.
2 Partially drain the cooling system.
3 Remove the air cleaner.
4 Disconnect the coolant hoses from the
automatic choke (where applica ...
Starter motor - testing in the car
Note: Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before proceeding.
1 If the starter motor fails to operate when the
ignition key is turned to the appropria ...
Minor body damage - repair
Repair of minor scratches in
bodywork
If the scratch is very superficial, and does not
penetrate to the metal of the bodywork, repair is
very simple. Lightly rub the area of the scratch
with a pa ...