Wagon Tailgate Trim Removal and Access

Having carried out this task recently, it has become apparent that the info provided in 700/900 FAQs,if followed, will most likely result in damage to the plastic trim which surrounds the tailgate release lever.

THERE'S A BETTER WAY.

The following applies to a 93 940 wagon, and I would think all 700 and 900 wagons.

You will need a small to medium flathead screwdriver & a torx screwdriver found in Volvo tool kits.

A CAUTION: When steps 1 to 4 are completed it will be time to remove the trim. This MUST be done by sliding the complete trim including the brake light in an upward direction. Doing this will disengage the 4 fragile plastic tabs that secure the top of the trim to the bodywork. Failure to slide upwards will cause the tabs to break.

Step 1. Open the tailgate fully.

Step 2. Remove the plastic rectangular shaped surround trim which is part of the housing for the lever which opens the tailgate from the inside. This surround is held by 9 shallow 1"(2.5cm) long plastic lugs.

When levering with the flathead screwdriver it is best to be doing so at the centre of these concealed lugs. The centre of each lug can be found using the following measurements-

TOP EDGE ie edge closest to the glass (3 lugs in total)
One lug can be found 2 3/4"(6cm) in from each side. The third lug is in the middle, 6" (15cm) from the edge.

SIDES
One lug on each side 1 1/2"( 3.5cm) down from each top corner.

BOTTOM( 4 lugs in total)
One lug can be found 1 1/2"(3.5cm) in from each side. The other 2 are to be found 4 3/4"(11.5cm) in from each side.

Start at the top right corner by sliding the flathead screwdriver between the carpet trim and the plastic surround 2 3/4"(6cm) from the side. Push the screwdriver in firmly and gently twist at the same time.You will feel the lug come free. Repeat this process at the centre of each lug, and the surround will come free.

STEP 3. Move to the bottom of the tailgate. With a 1/4 turn at each of the 4 plastic fasteners they can be removed.

STEP 4. With the plastic surround removed in step 2, this has revealed 2 torx head screws. Remove them. The only things now holding the trim are the plastic tabs at the very top. You must support the trim while you disconnect a power supply on the righthand side. This can be done with one hand. Once this is done it is time to gently push the complete trim upwards towards the glass to disengage the 4 fragile plastic tabs at the the top. The trim is light and will now come away.

With the trim removed it is a good opportunity to apply Loc Tite to the 3 screws that hold the wiper motor in place. They have a tendency to work loose. You will also find a small phillips head screw between the opening lever and the latching mechanism at the bottom of the tailgate. This can work loose. As it is housed in plastic, Loc Tite is not recommended.

A spray of lithium grease to moving parts is a good idea.

STEP 5. Reassembly.
On reassembly do not forget the need to reconnect the power supply to the window heater.

Hope this helps.

Take care,

JOHN H from DOWNUNDER