swapping over a tailgate

[BobbyT]

word up! just need some info on how to do this as at last i have found a mint chili red tailgate which i am picking up tomorrow, now i know i need to un-do the gas struts and the hinge and that should be that but what about all the wiring and the tube to the wash wipe? is there a connection inside the car?? any tips would be great! 

[Mikester]

Ive noticed if you use the front washers, then the back the back one takes some time for the water to get through, maybe that will stop water pissing into your boot, or you could just spray it dry first.

[Tribunius]

Ok I did this with mine.

First off depending on how the replacement was taken off you will have some prep work too do.

I'll assume that it was done the same way as mine, they just cut the connections at the point where they pass through the two black rubber hoses at the top corners of the door.

1. On the new door take off the trim. There is a whole load of stuff in there but what you are looking for are the plugs. These will be wrapped in yellow or gray foam. Also take off whats left of the rubber hoses.

2. Cut off the foam and disconnect all the plugs. Remove any sound insulation as it will make life easier. Access is fair difficult to some parts so you may need to take out bits like the lock body. (You might aswell take this out at any rate as you need to swap them around.) Also the harness is clipped to the inside of the door so you will need to undo these aswell being careful not to break the little plastic tab inside the clip.
Note: The connections to the rear heating grid are removed by pulling down. Then take off the rubber grommet and push through into the door. There should be a plug in the top section of the door for your top break light. Don't forget to disconnect the water lines (the thick white cables).

3. Remove the hinges from the top of the new door. This way there is less fiddeling around on the car with taking the roof trim off etc. However you will need to line the door up correctly so it closes and locks.

4. Repeat steps one and two on the old door. You will have to pull the wires out of the door up through the top corners. It takes a bit of messing about but you will eventually get them all the way up. Be careful at the holes for the heat grid wires.

5. Now you have to take the old door off. Have a budy hold the door while you remove the gas struts. To do this use a flat headed screwdriver to push the metal retaining clip up on the end connected to the old door. Caution don't push it all the way off or it won't go back on. Just push enough so that you can pull the strut off.

6. With a buddy supporting the door undo the nuts at the hinges. Take off the door and put the new one on. Be careful not to rest the edge of the new door on the ground or you will chip the paint. Also don't tighten the nuts full as you will need to adjust the door a bit from left to right so it closes.

7. Now simply do the reverse. Getting the wires down the sides of the door is a pain and it will take time but it can be done. Just push them down until you can pull them out at the bottom. Remember to pull the little extensions for the heating grid out of their holes. I found removed the round rubber bumpers at the bottom of the door to help. They just screw in.

8. Now just connect everyting back up. Plugs only go in one way so it is easy enough. Make sure you connect the water lines up before you test everything out.

9. The last step is to line the door up so it makes propper contact with the locking lug on the boot. This is just trial and error pushing it from left to right. Once done tighten the bolts in the hinges fully. Put a bit of touch up paint on the bolts as some of it will come off. And that should be it.

Now the disclaimer. I accept no responsibiltiy for any bits left behind or not working caused by following these instructions. This is only a rough guide taken from my own experience.

[iMation]

6. With a buddy supporting the door undo the nuts at the hinges.

That will be me then eh rob

[BobbyT]

yeah thats right stu! get the guns out! get some pics of your mk4 up!