Having said that, I lubed the heck out of the mechanism and all seemed well again for a few months. I did at least show the boss how to release the latch if it happened again.
Tired of the complaints, I ordered a new Volvo part. If the original was bad after 16 years, a new one was expensive but needed.
NOTE: Canadian Volvo owners, check Volvo parts on-line. 3 or 4 of the Canadian dealers sell parts at substantial discounts to counter prices. Cheaper than imported parts from US. Often with free shipping also!
I was not looking forward to this job as I hate old interior panels and flimsy plastic with clips that usually break. I had this off several months ago but forgot how.
Found the Vida instructions, printed off a hard copy and read them through. Highlighted a few points:
1) Remove the upper surround around the rear windshield first. Um...NO?? It instructs you to pull the lower 'legs inward. Maybe a 0-04 might do that (I have no idea) but the 06 the 'legs' are tucked under the lower section. Pulling the legs in would break both panels.
There is NO need to touch the top piece at all!!
2) Highlighted - Remove the x 4 T25 screws. 2 (one each side) and 2 in the bottom of the panel in recesses. Make sure to note that 2 of the screws are different lengths and where they go. So which of the 4 identical screws are the shorter ones??
3) Carefully grip the top of the panel near one corner and gently tug straight down. The clips came loose easily and then the same with the bottom edge. It may help to have a 2nd pair of hands as it is a fairly large panel to handle, but not heavy. If doing this outside and it is windy, then definitely have a 2nd person helping you.
4) Instruction - Remove the rod for the tailgate outer handle. No mention how!! What I did was loosen the T25 threaded screw in the end of the outer release latch on the inside. Don't remove it fully as you need to put a small screw driver between the plastic and the rod to pop it upwards to release it.
NOTE: When re-fitting, watch there is a notch in the which plastic clip where the rod goes into. It has to line up with the rod to allow the rod to push all the way back home!
The rod can then be removed as part of the latch system.
5) I used a fine Sharpie to circle the 3 x T40 mounting bolts. Have a flat blade screwdriver easily in reach or in a pocket to disconnect the wiring connector. This can only be done once the latch is out as you have to bend the 2 latch parts of the clip on opposite sides outward to release it. Can't get to the upper one with the latch in place. Remove the 3 x T40 latch bolts and removed them. The assembly can now be manouvered out by tipping the upper end downward and it comes out. You need to disconnect the cable connector now by bending the 2 latch ears outward.
You will now see the rod for the tailgate release in the mechanism. Make not where it fits!! Do this before removing it and not after as some idiot did!!
Swap to the new latch and as the good old Haynes manual says, fitting is the reverse of removal!
Remember to re-tighten the T25 bolt for the outside handle end of the release latch rod
6) Reconnect the cable connector. It should snap back together easily.
7) Now test the mechanism works! Flick the latch to the closed position and check it releases when you use the outside handle. Try a few times to make sure everything is back in place fully!
DO NOT re-fit the inner panel yet!! Close the tailgate and check the lock works electrically with the fob as it should. Also check you have no notice on the dash that the tailgate is not closed. You have to start the car to check that!9)Once all is good then re-fit the inner tailgate panel. Check the center alignment pins are aligned with the tailgate and then bump the panel face to snap them back in place.
10) Finally re-fit the 4 x T25 screws into the inner panel and you are done!!
This can be done in about 30-45 mins max.
Some further notes:
I was curious why the old latch was not working as it should. Shaking it showed a loose coiled spring inside the latch part of the assembly.
You can access this area by undoing the 2 sides of the plastic cover over the latch end and it slides off.
There are 2 x T20 screws in the back of the metal part of the latch. Remove these. NOTE: These screws ARE different lengths!! Make sure which goes in which end and mark them to remind yourself!
With a flat blade screw driver you can work and separate the metal lower part from the upper section. Inside the lower section I found a coil spring that should have 2 loops to hook over pins on the latch. One end hoop was broken off. I then bent that end with needle nose pliers to make a new hoop. One end fits over the latch end plastic from the bottom side, and the other end hooks over a brass pin on the casing above the release side of the latch. It is about 12mm long and has a recess around the end of it.
It is a little fiddly to re-fit, but once back in place, I tried the latch and it worked fine again!! I rebuilt it and then have stored it away for the future!!
Last thing, I lubed the latch with spray white lithium grease.
Hope this helps! Only wish I had taken my phone out with me when doing the job to document it!
Neil.