Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194), MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)

The steps may slightly vary depending on the car design.

How to change gas struts / tailgate struts on MERCEDES-BENZ VITO 1 (W638) [TUTORIAL AUTODOC]

Replacement: tailgate struts – Mercedes Vito W638. List of the tools you'll need:
Replacement: tailgate struts – Mercedes Vito W638. List of the tools you'll need:
Flat Screwdriver
Hydraulic transmission jack
All the parts you need to replace – Tailgate Struts for VITO Bus (638) and other MERCEDES-BENZ models
How to change Gas Spring, boot- / cargo area on Mercedes W638 Minibus 112 CDI 2.2 (638.194) – step-by-step instructions for straightforward car repair
Gas Spring, boot- / cargo area
How to change Gas Spring, boot- / cargo area on MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) – tips for proper car maintenance
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194)
Simple DIY car repair steps – Replacing Gas Spring, boot- / cargo area on MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)
MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)
How to change Gas Spring, rear windscreen on Mercedes W638 Minibus 112 CDI 2.2 (638.194) – step-by-step instructions for straightforward car repair
Gas Spring, rear windscreen
How to change Gas Spring, rear windscreen on MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) – tips for proper car maintenance
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194)
Simple DIY car repair steps – Replacing Gas Spring, rear windscreen on MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)
MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)
Replacement: tailgate struts – Mercedes Vito W638. AUTODOC experts recommend:
  • Right and left gas struts of the boot lid should be replaced simultaneously.
  • The replacement procedure is identical for the right and left gas struts of the boot lid.
  • All work should be done with the engine stopped.
Replacement: tailgate struts – Mercedes Vito W638. Recommended sequence of steps:
  1. How to change Tailgate Struts on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Step 1
    Open the boot lid.
  2. How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Tailgate Struts - step-by-step manuals and video guides
    Step 2
    Support the boot lid. Use a hydraulic transmission jack.
  3. Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Tailgate Struts replacement: free workshop manuals
    Step 3
    Release the circlip connecting the gas strut to the car body. Use a flat screwdriver.
  4. Changing Tailgate Struts on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Step 4
    Release the circlip connecting the gas strut to the boot lid. Use a flat screwdriver.
    Replacement: tailgate struts – Mercedes Vito W638. AUTODOC recommends:
    To avoid any injuries, be sure to hold the boot lid while demounting the gas struts.
  5. How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Tailgate Struts - online easy-to-follow instructions
    Step 5
    Remove the boot lid gas strut.
  6. How to replace Tailgate Struts on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Step 6
    Install the new boot lid gas strut.
    Replacement: tailgate struts – Mercedes Vito W638. Professionals recommend:
    To avoid any injuries, be sure to hold the boot lid while installing the gas strut.
  7. How hard is it to do yourself: Tailgate Struts replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Step 7
    Snap on the circlip connecting the gas strut to the boot lid.
  8. Need to know how to renew Tailgate Struts on MERCEDES-BENZ VITO ? This free workshop manual will help you to do it yourself
    Step 8
    Snap on the circlip connecting the gas strut to the car body. Use a flat screwdriver.
  9. Changing of Tailgate Struts on Mercedes W638 Minibus 1996 won't be an issue if you follow this illustrated step-by-step guide
    Step 9
    Remove the hydraulic transmission jack.
    AUTODOC recommends:
    Replacement: tailgate struts – Mercedes Vito W638. Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
  10. MERCEDES-BENZ VITO 108 CDI 2.2 (638.194) Tailgate Struts replacement: online guides and video tutorials
    Step 10
    Check the working condition of the boot lid gas springs after they are installed.
  11. Replacing Tailgate Struts on Mercedes W638 Minibus 1998 112 CDI 2.2 (638.194) by yourself
    Step 11
    Close the lid of the luggage compartment.
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DIY MERCEDES-BENZ VITO Bus (638) Tailgate Struts replacement - online guide
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