Thread: What happened to your D3/D4 today?

Originally Posted by LRD414

Details in this thread for a more permanent manual release cable:
Manual tailgate release D3

Refer to post #68 for a pdf document I created for the bike cable version.

Cheers,
Scott

I quite liked your method Scott, I'll most likely do something similar. Defiantly a must do mod if you have drawers or cargo barrier in place (or anything else that would limit your access to the rear trim with everything shut up.)

Originally Posted by John_D4

Any idea if the instructions would be the same for a D4?

Yes same. I have a D4.

Originally Posted by LRD414

Details in this thread for a more permanent manual release cable:
Manual tailgate release D3

Refer to post #68 for a pdf document I created for the bike cable version.

Cheers,
Scott

Thanks very much Scott. Another mod for the list. Cheers, Hawc

Done the re -o'ring of the front valve block today , pretty simple job , hardest part was getting the brass nipples to screw back into the housing without cross threading the plastic thread.

Did notice a very fine whitish coating on some of the orings and wonder if its the dissicant breaking down and getting spread thru the system over time. I have rebuilt the original compressor but the car is now 13yrs old so guess that its not a huge surprise for these things to start needing attention.

I would think the orings could have just been wiped clean , and a thin coating of lanolin or similar smeared back on and reuse them , but i had the kit so changed them out anyway.

Next is 2 new front wheel bearings when they arrive

Bulletman

Originally Posted by shanegtr

Had to fix a busted upper tailgate cable/latch today. So glad I dont have a cargo barrier or rear drawers to make life difficult. I'll defiantly be making plans to install a manual release when I get some time.

Great video Shane and inspired me to do manual release project today.

I’d had the failing slowly actuator replaced about 6/7 years ago and not sure if part was upgraded but the angle pin looked in perfect shape as I’ve been expecting it to break any day at worst possible time for last few years. I had no plastic weather sheet in there I assume they removed at the time.

The carpet liner disassembly is an absolute cinch 10 min job as you suggest with both tailgate doors open and a great opportunity to clean a few things.

First challenge was prising out the angle pin from the plastic jaws without breaking things. I had a box of tissues ready as I was sure this was going to end in tears. Crimp the jaws open with needle nose pliers then you can bend them out again later was the final solution.



I used a 24” wire fishing trace with loop ends. I just twisted one end on the line in front of the angle pin.The pin seems to snap at the bend so this section always stays on the wire as a good place to pull from.



Then the fun begins. I looked at @peterall post and since I don’t have a cargo barrier I wanted a discreet solution since this will hopefully be never used.

I routed the trace through the bottom part of the actuator box to come out near the wiring plug and tried feeding the trace out the existing cover panel holes at the end for the latch and the wire support lug.



Problem is it works silky smooth when you have the carpet panel off but every time I tried testing a solution from the inside in ‘emergency mode’ with the panel on and tailgate shut the trace was somehow choked and I couldn’t get it to open. Lower and outer edge options also suffer from being too far on the outside edge to allow any sideways pull leverage or if you try to come out in the carpet area snagging on the carpet gap flap which rides up high when the tailgate is shut.

So I pulled it apart again and this time routed the trace out the top of the actuator and up to top drivers side corner of the tailgate.



Drilled a small hole just under the white fastener and drew the trace through this hole which you can’t see in the carpet.






This keeps a nice interference free “pull” for the trace without snagging. Added a pull ring and pushed the slack in.


Refitted top cap to sneak the ring under.



How it looks inside when shut and a further pull line extension could be added for those in touring mode or with cargo barrier. Note it doesn’t interfere with the gap flap in the closed position.



Hope that saves some puzzling time for you.

Connecting to the actuator and reinforcing the cable end all looked too complicated to me. You can simplify the set up by connecting direct to the lock mechanism.

Then it does not matter if the actuator or cable fails and my trace line has a straight run and pulls freely.



Comes out here:



With tailgate closed:



The draw pins are just to hold in place with a bit tension in the locked position.

Ran the wiring and switch for my driving lights today. Waiting on the mounting bracket which hopefully will arrive this week.
The switch I had slipped perfectly into the notch just below the steering wheel.

Also put the Cel-fi Go in under passenger seat, although it’s got some issues which I’m a bit stumped on.

Caught up with some friends for Australia Day (is it still ok to say that?) today at Whitehills beach just South of Mandurah (photo below) - 1x D3 (me), 1x Colorado, and a couple of soft roaders with pretend 4WD (no low range, some traction aids, and not enough clearance). Pottered around there for a while and then got back on the main road and went to Myalup Beach. Then had some fun driving North from there to exit at Preston Beach. It was quite choppy with a lot of soft boggy sections and a few too many people camped in the wrong spots for my liking - like right next to the entry/exits! Being no fireworks in the city the beaches were quite full, and it was a case of slow right down to dodge the kids in some of the narrow sections.

Had an enjoyable day though, with the inevitable bogging of the softroaders if they slowed down too much (maxtrax and shovels prevailed) and overheating of their gearboxes, transmissions, etc (dash lit up with warnings) on the long soft, boggy sections. We eventually aired their tyres down to 12psi so they made a bit better going of it. Gotta love CVT's in the sand - not!

While we were at Whitehills, everyone mentioned how the D3 seemed to float over the sand making it look easy, while their cars vibrated and skipped around on the chopped up, corrugated sections. It was only reaffirmed at the Myalup section, when I had to take some passengers from the softroaders to lighten them on some tough sections, and they said the ride comfort between our vehicles was chalk and cheese. I think I may have inadvertedly converted a couple of guys to air-sprung, terrain response fitted vehicles! As an aside, I did see a new Defender near Myalup, but couldn't stop to say hi as we were in our 4 car convoy. It's nice to see the new ones getting out and being used in their intended role!

Whitehills Beach - Australia Day 2021.jpg