Technical help and FAQ

Changing the rear hatch lip seal

You will need

Allow 2 hours for the job

Remove the hatch from the car

Open the hatch.
Slacken all six phillips screws holding the hinge halves together.
Remove two screws from each hinge, leaving one screw holding the halves together.
Undo the two large bolts holding the gas struts to the hatch frame.
Leave the gas struts propping the hatch upright.
Undo the two remaining phillips screws and remove the hatch from the car.

Remove the old lip seal.

Using a small screwdriver, prise one end of the lip seal out of the channel.
Slide the screwdriver forwards to force the seal out of the channel.
After removing all of the lip seal, check for any small strips of rubber caught under the hidden edges of the frame. Use the tweezers to get them out.
Wire-brush the channel in the frame thoroughly.

Fit the replacement lip seal

Brush some soapy water onto the end of the lip seal for about 12 inches.
Start pressing the new seal into the channel at the central point between the two hatch handle pillars.
Let the seal cant over towards the raised edge of the hatch frame, so that the edge of the T section slides into the channel, and press the opposite edge down into place with the dinner knife.
After getting 6 to 8 inches in place, move ahead about a foot and press the seal into place, then work backwards, fitting the seal. This will prevent stretching.
You might find yourself changing sides at the corners if the seal has a tendency to pull to one side or the other. Take care not to stretch the seal at the corners.
Cut off the surplus seal and finish the butt joint with a small amount of Superglue.

Check the rear hatch hinges before refitting

Make sure that each hinge in the rear section of the car pivots freely, and slides from side to side easily. Free up if necessary.
Slide the hinge until it is nearly off the pin, and then apply grease to the exposed pin. Slide the hinge back and forth to distribute the grease.

Refit the hatch.

Offer the hatch up to the rear of the car, and support it on your head while loosely attaching the gas struts to the frame.
Using a tapered bar or small phillips screwdriver, line up the hinge halves for one side of the car, and put in one of the phillips screws.
Repeat the process for the other hinge halves.
Fit the remaining 4 screws, but no not tighten firmly yet.
Do up the bolts holding the gas struts finger tight, then close the hatch.
Tighten the phillips screws in the hinge halves from inside the car.
Open the hatch again and tighten the bolts in the gas struts.