Bongo Fury

I have a tailgate that I want to install - was hoping for work sheet but can't locate any. Has any one removed and Installed a tailgate? Any suggestions or tips would be very welcome. thanks

they are bloody heavy so be careful.

Tailgate installed successfully - 4 of us just in case with one wooden support for stability and support the weight. The removal was done by disconnecting the the washer and electrics. The upper bracket screws (10mm) were loosened. The struts were released at the tailgate end (10mm). Then with the tailgate supported each side and also at its base the bolts retaining the two brackets were removed which released the tailgate. The replacement was fitted in reverse order. One issue arose the wiring loom for supply to the tailgate had been butchered - OS lower and upper trim panels removed as the wiper and HRW did not function - scotch locks had been used into the main loom then additional scotch locks and wiring used to circumvent the loom connectors. a proper mess that will take some sorting out. My replacement tailgate did not have any holes to attach the spoiler not noticed by anyone until it was time to fix the spoiler. The dealer had left the rear wiper on with the blade & arm. The arm was badly corroded, we found the reason, the arm was seized solid. Using the trusty wiper arm removal tool (that doesn't fit on the front arms) and buckets of release fluid still would not release. Earlier today using pointed tool I scraped the rust away from the bottom of the thread applied the tool and more release fluid. Still stuck so decided to leave it under pressure from the tool and opened the tailgate to put tools away, as I shut the tailgate the wiper arm popped of the spindle. Tomorrow it will be wiring loom time - I am not looking forwards to that.

Sounds a good job
And the annoying little extras that always pop up with this age of vehicle dealt with
Well done

Did you remember to swap the lock barrels over ?

Excellent thread. This would make a good factsheet if there isn't one already.

Yes did the lock barrel so I still have single key system. The supplier had left the lock so when the barrel was fitted the Auto door locking by the key worked fine. I didn't get any remote when I bought the Bongo and as yet haven't located any receiver to suggest that it had CDL from manufacture. Combination of family visitors and weather today deferred the wiring issues. Tomorrow examine the wiring mess closely to form a repair plan, have put enquiries out for a front to rear loom specific for the tailgate. The OE loom has been bridged with scotch locks to the tailgate also two wires in the loom have been cut and left unconnected. what remains of the loom may make replacement the best option for permanent repairs.

Just been talking with Mark in Leicester (breaker) about another front to back loom. It seems that the door and tailgate looms are sometime found brittle cracking and so on - strongly suspect my front to rear had done so. Explains the multitude of of scotch locks and over use of red wire. The HRW didn't work on the previous set up ( despite having been replaced last year) so the way forward is to repair/splice from the OE loom. Task one check the CFD to determine colour(s) and function - task two open loom and label (masking tape) identities, wiper, HRW, number plate lights and of course auto door locking. I am going in chaps! CLEAR PROP

Vehicle wiring loom 96 2.5td 4wd - the loom to the TAILGATE followed back MATCHES the 1997 - 2001 current flow diagram. They are as follows:

Page 64
Rear Wiper - White/violet = Ign Live ----Violet/white = switch (Fuse 13)

Page70
Number Plate lights - Red/Black = supply-------Black = earth

Page94
Heated Rear Window (HRW) Thick Black/Yellow = live (may be a Black/Blue) ------ Black = earth (fuse 22)

Page 108
Central Door Locking (CDL) Red = From control unit supply -------- Red/green = return to control unit.

Firstly good news for those who may have problems with the loom to the tailgate. Behind the RH rear panel there are 3 connectors slightly to the front of the wheel arch. Detach these and you should have the rear section of the main front to back loom. After assessing the amount of scotch locks and the addition of excessive red cable I elected to identify the function by pairs and remove scotch lock, excess cable and the tangled mess. I used male/female bullet connectors (Halfords) to displace the scotch locks. Although a real fiddle and skinned/scratched fingers the best that could be done in a confined space with the bullet connectors was achieved. All functions were operational with the exception of the high level brake light which being part of the spoiler were isolated and capped. I have one strange red wire that goed into the wheel arch and disappears - I think this might be for the accessory rear fog but didn't have time to resolve the mystery. Hoping we may have time tomorrow to resolve this one - the rear fog was on the wrong side which I resolved at an earlier point.