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Curing rattles, my story so far
OK, having had mine for a couple of months now, and with spring around the corner, I'm starting to "add stuff" with regard to using it occasionally as a mini camper as well as my daily driver and working "van".

Mine is the "Desire" type, with the fancy roof, with all the storage cubbies and lights and vents n stuff = very handy for what I will be using the thing for Cool 

However, it does rattle a bit over bumps, not too bad, but I thought I would start to chase them down and sort them, one by one, starting with the worst. So, seats folded forward, friend in the back, set off down a bumpy country lane. We discovered quickly that the main culprit was NOT the roof, but the tailgate.

Back at base, removed the plastic cover and had to remove the thin foam insulation (damaging it in the process). Right away noticed that there are some metal "Z" shaped brackets that hold the rear skin of the tailgate to the internal skin. Where they are supposed to be bonded to the outer skin, they had come adrift and causing some rattling.

The fix = warm the area up with a heat gun and use a glue gun to inject glue, whilst holding the two surfaces apart. Allow them to clamp back together (you'll see what I mean if you do this job) and all is good again. I didn't bother with replacing the damaged thin foam sheet, I just glued some thick plastic sheeting (from a fertiliser bag) over the holes.

I had broken 3 of the clips that hold the interior trim onto the tailgate, but these are easily and cheaply available from Ebay link =

Next, I'm going to look for any other rattles and will report back.

Regards to all,
John - (2005 2.0HDi with Modutop roof, mini camper).


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