Installation Guide Rear Pull-Out: Here's How to Install It in 10 Minutes
Tailgate Extension Installation Guide: How to Mount It in 10 Minutes
Tailgate extension unpacked, instructions nowhere to be found, YouTube not helping. Classic. Here's the step-by-step explanation so you can have it in your van today – not next Saturday.
Applies to: 040 Parts tailgate extension in VW T5, T6, T6.1 California (Comfortline, Ocean, Coast) with the 750mm extension.
What You Need
- The 040 Parts tailgate extension (everything included, no extra purchases needed)
- Allen key set (sizes 4, 6, 8 mm)
- Lubricant / grease (optional, but recommended)
- A second person for insertion (recommended, not required)
- About 10 minutes
Step 1: Prepare the Vehicle
Open the tailgate, clear the load floor as much as possible. You need access to the floor rails (left and right in the cargo area). Check that the rails are clean and free of dirt.
Important: Don't remove anything that isn't necessary. You mount the extension onto the existing vehicle structure – no panel removal needed.
Step 2: Understanding the Floor Rails
The California cargo area has longitudinal rails on the left and right where you can insert and attach the extension. The plastic washers that are included go between the metal washers and floor rails – they protect the rail from pressure marks.
Order from top to bottom: Screw → Metal washer → Plastic washer → Floor rail.
Step 3: Positioning the Extension
Lift the extension from the back into the cargo area and set it onto the floor rails. The extension rests on the rails – it's not tightened yet. First align, then screw tight.
Alignment: The extension should be parallel to the side walls of the vehicle. Briefly check with a tape measure whether the distance to the wall is the same on both sides.
Step 4: Screwing It Down
Tighten screws by hand – don't fully tighten yet. Check the alignment again. If everything looks good: tighten all screws evenly. Don't finish one side completely and then do the other – work alternately so the extension doesn't warp.
Torque: Don't use force. The tailgate extension is aluminum – tighten it, yes, but don't use an impact wrench.
Step 5: Test the Mechanism
Before first proper use: Slide the extension in and out several times. It should run smoothly, nothing should jam, nothing should rattle.
If it's stiff: This is usually caused by dirt or sand in the guide rails. Clean the rails, then lightly grease. This helps in 90% of cases.
If the mechanism jams: The most common cause – the extension was inserted before the levers were operated. Always operate the two blue levers first, then insert. Otherwise pressure builds up on the mechanism and it blocks.
Step 6: Install One-Hand Lock (Optional)
If you ordered the 040 Parts one-hand lock: Installation time under 2 minutes, no drilling, no gluing.
The lock hooks directly onto the existing lever mechanism. Done. From now on you can open the extension with one hand – practical when you're already carrying things in your arms while unloading.
Important: This version of the one-hand mechanism fits only 040 Parts tailgate extensions with the original levers. Not for third-party manufacturers.
Step 7: Insert Anti-Slip Mat
The anti-slip mat is exactly sized to the extension tray – no cutting, no adjusting needed. Just insert it. It sits firmly, doesn't rattle, and protects the aluminum tray from scratches. When cleaning, simply remove, shake out, and put back in.
040 HACK: If the extension becomes stiff again after prolonged use, sand usually gets into the guides. Clean and re-grease once a month – this keeps the mechanism smooth for the next decade.
Common Installation Mistakes
Mistake 1: Forgetting the plastic washers They end up somewhere on the load floor and three weeks later you wonder what they're for. Answer: Rail protection. Simply unscrew and attach them again.
Mistake 2: Latch collides with screw If the extension can't be unlocked after installation, check if the latch is colliding with one of the rear screws. Slightly rotate the screw head until the extension can slide over it again.
Mistake 3: Wire bends This happens when moving parts are insufficiently lubricated or the latch wasn't fully unlocked. Lubricate and ensure complete unlocking.
Lost the Installation Guide?
No problem. Write to us at shop@mixcover.de with your order number – we'll send you the digital version. Or stop by directly in Hamburg (Mon–Fri, 9am–3pm, just let us know beforehand).
Matching Products:
Built for your next story – Your 040 Team
