Tailgate support cable broken

TAILGATE SUPPORT CABLE BROKEN

Model

Defender XD Only (‘Wolf’ MOD Vehicles)

Affected vehicles

All XD variants with drop down tailgate and soft top.

Date

1999-07-28

Reference

Bulletin 0042, CDS ref L8537bu

Bulletin text

Defender XD Only (‘Wolf’ MOD Vehicles)

AFFECTED RANGE:

All XD variants with drop down tailgate and soft top.

PROBLEM:

TAILGATE SUPPORT CABLE BROKEN

CAUSE:

If a heavy load is applied to the tailgate when open, the end of the cable attached to the body can jam on the seal due to body flex at the mounting point.

As a result, when the tailgate is closed the cable is damaged.

ACTION:

Remove both tailgate cables and fit new brackets and cables as follows:

1. Support tailgate to prevent damage and remove cables.

2. To create new upper fixing points for the support cables, drill out the upper rivet on each wheel arch box, (39mm below top face of wheel arch box, A in illustration 1) and enlarge holes to 10mm diameter.

3. Fit M6 nutserts, part number AWR6715, into the 10mm holes and pull up to secure.

Bulletin N o : 0042 L8537bu 1 28.07.99

6. Using M6 20mm screws FS106201, secure the forward end of brackets to wheel arch boxes with plain washers MRC5529 and M6 nyloc nuts NY106041. (Refer to illustration 3 - view of right hand bracket from above.) Finally, torque all M6 fixings to 6Nm.

7. Fit cables RRC5539, assembling cables to brackets as shown in illustration 3, using M8 nuts NT108041 to adjust clearance so that cable ends are free to rotate on screws FS108251. Torque M8 fixings to 12Nm.

PARTS INFORMATION:

Part number RRC5539 Cable - tailgate BHU710010 Bracket - cable FS106201 Screw - M6 x 20mm AWR6715 AVK Nutsert - M6 MRC5529 Washer - M6 NY106041 Nut - nyloc - M6 FS108251 Screw - M8 x 25mm NT108041 Nut - M8 WC108051 Washer - M8

4. Fit brackets BHU710010 horizontally using M6 x 20mm screws FS106201 to secure rear of brackets to nutserts, (refer to 2 for correct orientation, right hand bracket shown).

5. From the brackets, drill forward fixing holes 6.5mm diameter into wheel arch boxes, (refer to illustration 2).

Description Qty/Veh 2 2 4 2 2 2 2 2 6

WARRANTY CLAIMS: Use Complaint Code: 9F9D

Use S.R.O.: 76.40.89/36 Time allowance: 0.30Hrs