How-To Remove and Replace the Rear Hatch Options

[Overkill]

Alright guys and gals, I have done my fair share of searching the interwebz for a detailed how-to thread on this and the closest thing that I have found was Malpaso's attempt.

I recommend having at minimum two people to do this job. A 3rd person would be nice, but not necessary.

Tools Needed

12mm wrench
10mm Socket wrench w/ extension
Flat-head Screw Driver

Step 1. Raise the hatch, and crawl into the back. I found that taking the spare out to do this is helpful, but not necessary as long as you mind your footing. You do not want to put your full weight on the area the spare is in, as you may push the steel undercarriage out slightly.

Step 2. Unplug the three plugs attaching the hatch to the car. The passenger side plug is for the window defroster. You will need to pull the wire out gently and unplug the connection. (this connection most resembles the way the lighter fits into the lighter plug.) The center plug and hose are the rear windshield wiper fluid hose. You will need to pull the hose out gently and disconnect the side of the hatch hose from the hose connector piece. (this hose connector piece is a small piece of metal that has bulges at both ends allowing you to connect one hose to another.) The driver side plug is for the rear hatch brake light and the rear windshield wiper motor. Pull the wires out slowly until you get the connectors out of the plug hole. You will need the flat-head screw driver here to lift the snap on the plug up so that you can disconnect them.


This is the hatch hinge and 12mm bolts (attached)


This is the hatch hinge and 12mm bolts. (detached)


This is the Driver Side Plug (attached)


This is the Driver Side Plug (detached)


This is the center Rear Windshield Wiper Fluid Plug and Hose (attached)


This is the center Rear Windshield Wiper Fluid Plug and Hose (detached)


This is the Passenger Side Plug for the Rear Defroster (attached)


This is the Passenger Side Plug for the Rear Defroster (detached)


Step 3. With the hatch raised, the plugs disconnected and the second person outside the vehicle holding the hatch in place, use the 12mm wrench to loosen the bolts from the hatch. Once all the bolts are loosened and taken out, the person on the outside of the car will need to hold the hatch in place. Leaving the hatch shocks attached will help the person outside the car hold the hatch up until you can get out of the car and move to step 4.

NOTE - The nuts that bolt to the hinge portions that are under the headliner do not need to be removed to complete this task. In the case you want to remove the hatch hinge, you will need to remove some of the rear plastics, and the rear portion of the headliner to get to the nuts that hold the hinge to the car.

Step 4. If you are planning on replacing the hatch shocks, or the replacement hatch has shocks already attached, use the 10mm socket-wrench with extension to remove the shocks from the rear of the car. If you leave the shocks attached to the hatch you are removing, I suggest using tape to secure the shocks to the hatch because you would not want the shocks to accidentally break the hatch glass. Now that the old hatch is removed, set it aside.

Step 5. Attaching the replacement hatch is basically these steps in reverse, however in a slightly different order. I suggest that the hatch be bolted to the hatch hinge first. This will require patience and some strong arms. Next I would suggest attaching the hatch shocks. This will allow you to have the hatch in place while working on the plugs. If you attach the hatch shocks before the hatch is bolted, you will have a difficult time aligning the hinge holes to the bolt holes on the hatch. Secure the plugs, and you are done. To make sure the plugs are all connected correctly, be sure to test the brake light, and the rear wiper. You will have to wait for a foggy/frosty day to test the hatch defroster.


This is the old hatch


This is the new hatch

Total time it took me and my wife to complete was about 2 hours, but I had a lot of glass to clean up.

[cheela]

nice write up! pics of the plug attached and detached really help.
and I see you got the two post spoiler with your new hatch too. nice!

[Overkill]

I see you got the two post spoiler with your new hatch too. nice!

Thanks! Yeah, I am going to get the riser blocks soon.

[jordisonjr]

This should be stickied! Solid Write Up