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:
Engine/automatic transmission assembly - reconnection and refitting
1 Reverse the removal procedure described
in Section 12, noting the following points.
2 Check that the engine adapter plate is
correctly positioned on its locating dowels.
3 As the torque converte ...
Routine maintenance and servicing
This Chapter is designed to help the home mechanic maintain his/her vehicle
for safety, economy, long life and peak performance.
The Chapter contains a master maintenance schedule, followed by Sect ...
Engine Coolant Temperature (ECT) sensor - removal and refitting
Removal
1 The ECT sensor is screwed into the inlet
manifold.
2 Disconnect the battery negative lead.
3 Partially drain the cooling system as
described in Chapter 1.
4 Disconnect the sensor wirin ...