TheSamba.com :: View topic - Removing rear hatch hinge without ripping headliner

Thu Aug 30, 2012 8:12 pm

So the other week I tried to close the hatch on my Squareback and the hinge on the drivers side bent and started to bind to the point that I needed to use a pair of channel locks to pull the hinge down and close the door. From that point it became difficult to close unless I put something to block it from fully extending and binding further. Well one time I forgot to do that and it turned out to be the last time as the hinge bent to the point that it's no longer usable. I purchased a hinge from a parts car (thanks Boo-Koo-Z) and intended to replace it but am concerned as the headliner was done not long before I purchased the car. There's just a narrow slit in the headliner that allows the hinge to move with hardly any access to bend the torsion bars. Would it be feasible to use a heat gun to heat the headliner adhesive and separate from the edge of the roof? Would I need to remove the rear side window in order to be able to pull the headliner back to gain access to the torsion bars? I've read a few threads here from folks that have swapped hinges, but in all of those it appears the headliner was already toast.

Thu Aug 30, 2012 9:25 pm

My square does the same thing. I cut a piece of dowel to put in the hinge to keep it from extending all the way and the other day I walked into the edge of the hatch because it sits so low.

Fri Aug 31, 2012 8:19 am

I almost did the same thing until I realized it wouldn't help align the hinge so it would close properly and not chip the new paint job.

Tue Sep 04, 2012 4:39 pm

Well I had a buddy come over on Monday and we spent a few hours trying to get the torsion bar back into the notch in the roof with no luck. Getting enough tension on the torsion bar is not the problem. Getting it back into the notch once it's tensioned is the problem as you can't push it any farther up. It may require the VW 709 tool Bentley calls for, and I can't find that anywhere. I tried to bend several screwdrivers but the screwdrivers either snapped or were too strong to bend.

Here's one pic (you can't see the notch I'm talking about because it's obscured by the headliner)

Has anyone fabbed their own VW 709 tool? How'd you do it? If it's for sale, let me know :)
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Tue Sep 04, 2012 5:06 pm

So we need a special tool to replace the hinges?

I found this in the gallery:

http://www.thesamba.com/vw/forum/album_page.php?pic_id=637775

Tue Sep 04, 2012 5:07 pm

Found this too!

http://www.hallvw.clara.net/technical/tailgate.htm

Tue Sep 04, 2012 9:17 pm

Yeah, I saw those but thanks for sharing anyway. The instructions on Dave Hall's site were helpful especially while disassembling the spring, but they make it sound like it's no big deal to reinstall the torsion bar. Maybe it isn't with the right tool. Speaking of which, I am probably going to take some measurements and then show the pic to a machine shop near where I work and see if they can make such a tool.

Wed Sep 05, 2012 12:39 am

IIRC VW 709 wasn't actually supplied by VW, it was one where they gave you a template and you make one. It's basically an "S" shaped screwdriver. I'll almost bet a brake adjusting tool would work...

http://www.ebay.com/itm/Vintage-Blue-Point-by-Snap...500wt_1202

Wed Sep 05, 2012 12:43 am

Well, well, looky here:
http://www.thesamba.com/vw/archives/manuals/local_manufacture/tools-700-749.pdf

Second tool down. Even tells you how to make it, with dimensions! :D

Ain't the Samba great?

Wed Sep 05, 2012 7:48 pm

I have a tool that I picked up for installing weatherstrip and glass that has that same shape, but with a sharp tip.
I bet you could take the tip off it with a grinder and walla!
Now if I could only remember where I purchased it????

Wed Sep 05, 2012 8:02 pm

Tram wrote: Well, well, looky here:
http://www.thesamba.com/vw/archives/manuals/local_manufacture/tools-700-749.pdf

Second tool down. Even tells you how to make it, with dimensions! :D

Ain't the Samba great?

Gurrrrrreat!

Wed Sep 05, 2012 8:40 pm

Tram wrote: Well, well, looky here:
http://www.thesamba.com/vw/archives/manuals/local_manufacture/tools-700-749.pdf

Second tool down. Even tells you how to make it, with dimensions! :D

Ain't the Samba great?

That's awesome. I'm going to see about getting that tool made tomorrow and will report back.

Thu May 29, 2014 1:53 pm

Hey guys,

I'm having this same problem unfortunately. Is that special 709 tool absolutely necessary or are there any workarounds? Are there any tips to getting the torsion bar to line back up? Thanks

-T

Sat Feb 20, 2016 6:47 pm

I got the tension loose with a very large (2ft) screwdriver, but I need someone to get the clip off as this takes too much leverage to keep the tension. Not ideal, but if you have two people, and a massive screwdriver, you should be able to get it done. Unfortunately, the only other person nearby is my wife, so I need to bribe a friend to come help me... luckily I know a guy with a weakness for good rum.