V60 - power tailgate sinks a few inches after opening

[redfazer]

OK, encouraged by @PUFFLING, I had a go.

Important points:
1. No need to touch the inside of the car or wiring. I wish I hadn't, still trying to get it back together
2. If the spring is broken and the strut isn't working, the spring is no longer compressed, so safe (IMO).


So,
1. Prop the tailgate up securely.
2. Remove both ends of the strut
3. Slide off the 'weather seal' end cap - pic cap.jpg
4. Undo the 'clips' holding - pic unclipcover.jpg
5. Pull apart to see - pic insides.jpg
6. You'll see breaks (I had 6!!) - pic breaks2.jpg
7. 'Unscrew' the spring so the breaks are separated and tiewrap. Ensure a decent overlap. A dab of mig-weld would be great but I don't have one - and there maybe an issue welding a possibly galvanised spring as I think it produces cyanide gas!! - pic tiewrapped.jpg

That's pretty much it - and as the saying goes, refiitting is a reverse of removal

I only did 4 out of 6 breaks as the last 2 were in the 'tight end' of the spring and I couldn't easily unscrew it as I'd already done the others so it was getting compressed. Maybe if I'd have started at that end I'd have been OK. Doesn't seem to affect it though.

I had to give the tailgate a push to close the first time - I'm guessing the tiewraps needed seating away from the casing. Seems to be working nicely at the moment - and it's a quick job if it needs doing again.

[redfazer]

And 2 more pics - the prop and tools I used

[Number 6]

All we need now is for Volvo to allocate a Part Number for the broom handle and we are all good to go!

P.S no to welding, its a stress steel, this will cause hydrogen embrittlement, and you will a have a bigger spring jigsaw.