4104 Engine Door Lifts

gus · October 15, 2007, 07:29:18 PM

I just installed two gas lift struts from an '88 Dodge minivan on my 4104. I extended the original top mechanical brace mounts about 1.5" perpendicular to the door so that now the gas struts not only lift the door but they hold it closed due to the geometry of the mounts.

I used the Dodge struts because I happened to have a couple I had removed from my minivan when they would no longer hold open the tailgate.

I also removed the original mechanical door locking bar which was a real pain to operate.

If anyone is interested I can email photos and send exact measurements.

Flyboy · October 15, 2007, 08:26:11 PM

Hi Gus,

Please e-mail me the pics of the whole procedure.

I will be doing my 4104 door soon as it's starting to settle when opened.

skedlies@yahoo.com

Thanks in advance.

Aron.

John Z · October 15, 2007, 08:37:50 PM

Hey Gus, sounds pretty neat. How about putting some pics up here or on the 4104 web site?

JZ

zubzub · October 16, 2007, 09:20:11 AM

That sounds good, also while you're at it how about some pics of the alternaor set up you did when you pulled the generator on the 6-71?

jeepme · October 16, 2007, 10:12:59 AM

Gus, I'd be interested in pics if you don't mind. Are the struts strong enough to hold the door shut? Sounds like you might find the door open after a rough road

Jason Whitaker
4104

gus · October 17, 2007, 04:19:56 PM

I have no idea how to make this info available to download or how to place photos on the forum!! I can post the measurements here and send the photos by email.

I used the original (I assume mine are original since I've never seen another 4104) mounting holes with bolts to hold the Dodge struts since they have holes and are not the usual ball snap-in mount of more modern struts.

I'll measure the struts tomorrow but I have no idea of their capacity in lbs. I'll also measure exactly and photograph the extensions I added to the door mounts.

I used 5/16" bolts in the original 3/8" bolt mount holes to secure the extensions plus drilled a hole for a 3/16" bolt to keep the ext from rotating.

They hold the door very secure because the extensions result in an over center geometry when closed. It takes a bit of effort to open the door for the first 6-12", but after that it rises on its own and ends up just about perpendicular to the rear.

This is really a great convenience and was so simple to add. If my mounts are original it will be just as easy for anyone else.

I can make photos of the alternator setup also but it was there when I got the bus.

gus · October 18, 2007, 06:50:44 PM

I sent all this info to Gerald Norman's 4104 website because he knows how to make it downloadable and I won't have to keep sending it by email.

The link is
http://www.pd4104.com/modules.php?op=modload&name=Forums&file=viewtopic&topic=31&forum=12

and this is a great website for 4104 owners or wannabees.

Zub,

I'm sending you two photos of the alt installation. It is very hard to photograph because of the location but they turned out ok.

jeepme · October 18, 2007, 09:39:53 PM

Thanks for taking the time to upload all that Gus! It's appreciated!

Jason

gus · October 19, 2007, 06:39:44 PM

It is now posted on Gerald's 4104 website but I wasn't able to copy the photos, only the text. If any of you have the same problem let me know and I'll send the photos by email.

I asked him to make the info downloadable but so far he hasn't.

I was a pretty surprised at the interest in this as I assumed most people had already done it since it is so easy and the engine door is a such a pain to open. I just lucked out and happened to have the right struts and guessed at the correct length for the bracket extensions. I no longer dread having to open the engine door!

FloridaCliff · October 20, 2007, 07:31:05 AM

Gus,

Whats the #'s or model on the gas strut itself?

My 4905 has some but the are week.

The numbers and type are worn off.

I bet the Tokico's i put on the bay doors would hold it up, but curious what you have.

Cliff

gus · October 20, 2007, 08:53:08 PM

Cliff,

I'll check out the numbers tomorrow if they're still there. I've replaced so many (I have two Chrysler minivans) that these probably don't have the original OEM p/n.

The struts measure 23.75" open and 14.25" closed

You can probably find them at Auto Zone or any auto supply store since all you have to do is ask for a '88 Dodge rear hatch lift strut. I also have an '86 Ply minivan and they both use the same strut.

WalMart used to carry them but probably doesn't anymore because they are such old models.

gus · October 21, 2007, 06:55:50 PM

Cliff,

My two struts are different, neither is original Chrysler. One has the mark AVM and #55230-A.

The other one is #4775 0190 with that wide space between digits, no other markings.

As I said, just ask for a liftgate strut for an '88 Dodge Caravan minivan or for an '86, they're the same and probably are the same for 20 yrs of vans. Just be sure to get struts with bolt holes because they are easier to mount on the bus than the ball/socket type.

I would really like to know what the rated pressure for these struts is but I'm sure the parts people have no idea. My guess is 160-220lbs but that is purely a guess.

I asked Gerald today to add a bit of info to his website after I discovered that the door was banging against the bottom when it closed. I'm sure it isn't there yet because I just emailed it to him tonight.

I hope you all were able to download the info from Gerald, this is such an easy job for the great benefit it produces, that door just about wore me out when I first got the bus two years ago. I had the struts on the original mount holes all this time but just made the extension modification a few days ago. It makes the effort involved even less and it is great to get rid of that latch.