Cali Tailgate can’t open due to fouling Caravan handbrake.

[Damon18]

A week ago we attached our caravan to the Cali and setoff for a week’s holiday in Cahors.

On route we stopped to let the dogs out for a pee, and stupefaction, we found that we couldn’t open the rear tailgate as it fouled on the caravan handbrake (on or off) .

Only solution was to unhitch the caravan and relocate the dogs and their cage to the area behind the front seats, this meant that we couldn’t access the rear seats or the frig etc.

Our Cali is factory fitted with the VW removable tow ball, and the Caravan with an AL-KO AKS 3004 stabiliser (used by many caravan makers).

I’ve checked and our car trailer which we use to trailer our old MG will be even worse.

Has anybody had the above problem, and if so, is there a solution (besides changing the caravan) .

Thanking you in advance

 

[GrannyJen]

I have yet to find a solution.

My dogs sit on the back seat and I have to think about everything I may need from the back before hitching up.

 

[Max-Felix]

Do you have any pics? If it is only the caravan handbrake (that presumably operates a cable) fouling the tailgate then I am sure a small custom trailer manufacturer or similar could design and fit a relocation workaround?

 

[briwy]

Not familiar with caravans but would it be possible to shorten the lever enough to open the tailgate and carry a lenght of tube to fit over the lever to operate the brake?

 

[bigmac77]

How far would you have to move the caravan away from the Cali to get it to open?

 

[Damon18]

I have yet to find a solution.

My dogs sit on the back seat and I have to think about everything I may need from the back before hitching up.

Sorry to hear that you have the same problem.
If I find a fix I'll let you know.

 

[Max-Felix]

Pics?

 

[Damon18]

Do you have any pics? If it is only the caravan handbrake (that presumably operates a cable) fouling the tailgate then I am sure a small custom trailer manufacturer or similar could design and fit a relocation workaround?

I've attached a photo, which I hope illustrates the problem.
The handbrake is part of a complete AL-KO assembly, the handbrake has a gas strut attached to keep it in position (no ratchet), rather complex and is also part of the caravan inertia/momentum braking system.

 

[Max-Felix]

Piccy no worky...?

 

[Damon18]

Pics?

 

[Damon18]

Piccy no worky...?

Sorry resent.

 

[Damon18]

How far would you have to move the caravan away from the Cali to get it to open?

Need at least 7cm to allow the tailgate to open when "handbrake off".
Would need more with "hanbrake on" but this is not an issue as only really used when detaching caravan from vehicle.

 

[Damon18]

Not familiar with caravans but would it be possible to shorten the lever enough to open the tailgate and carry a lenght of tube to fit over the lever to operate the brake?

That was my first reaction, but the handbrake is fitted with a gas strut and it's all seems to be an integral part of the caravan inertia/momentum braking system.
I'd also be worried about the French Transport Dept (DREAL) with whom I've had dealing in the past, if I modified the caravan without passing through an rehomologation process (been there and it's not always easy with French red tape) it could get nasty in the event of an accident.
I think I'll contact AL-KO (manufacturer of the system) to see if they have a longer homologated version which would move the caravan back from the tailgate.

 

[Max-Felix]

It's such a relatively tiny amount that needs removing - I'm sure if you look at the handle/ram/linkage set up it must be only a very small adjustment/modification or chop that is needed to make it work - done properly no-one would ever know if something had been moved or shortened by an inch or so and nor should it matter anyway.

It almost looks like with the HB off you could push down further on the lever with some weight to force it down and give just enough clearance anyway?

Another alternative may be to find a removable towbar another inch or so longer? These will be made for all the large car companies by other major manufacturers and presumably have a common quick release/attachment mating point so may be swappable?

 

[Damon18]

It's such a relatively tiny amount that needs removing - I'm sure if you look at the handle/ram/linkage set up it must be only a very small adjustment/modification or chop that is needed to make it work - done properly no-one would ever know if something had been moved or shortened by an inch or so and nor should it matter anyway.

It almost looks like with the HB off you could push down further on the lever with some weight to force it down and give just enough clearance anyway?

Another alternative may be to find a removable towbar another inch or so longer? These will be made for all the large car companies by other major manufacturers and presumably have a common quick release/attachment mating point so may be swappable?

Thanks for the comments.
See what you mean about pushing down on the lever, have tried and it won't drop any further as rivited gas strut stops any movement.
Looked in owners manual for the any adjustment on the hitch but nothing mentioned (only maintenance advice). Have sent email to AL-KO technical services for possible solutions (wait and see).
Went to VW and asked about longer removable towbar but no luck there.
They have a fixed towbar arrangement for the professional market (Transporter) which may do the trick, but at a price (will consider if no other options).

 

[Damon18]

UPDATE.
ALKO have written back to say they have never seen this problem (strange) !!!
We have bitten the bullet and ordered a fixed professional type towbar from VW.
Saw this fitted to a T6 on the dealers park and it is sufficiently far away (measured to be sure) from the tailgate to allow it to clear the handbrake on our caravan, it's not very aesthetic, but beggars can't be choosers.
Will cost 750€ including fitting, but at least we should be able to sell the detachable which should reduce the overall spend.

 

[B J G]

Bit late in the day but I fitted a Winterhoff WS3000 Stabiliser Coupling to a caravan a few years back and it was longer (moved the caravan away from the car) by quite a few mm's than the original non stabiliser Alko coupling.
Also it used to be the case that a towball with a longer neck had to be fitted to the bolt on towball type towbars if an Alko stabiliser coupling was used. That meant that the caravan was further away from the towing vehicle.

https://www.ebay.co.uk/itm/Towball-...599624?hash=item20b66dc108:g:tBcAAOSwySVaIYU6

 

[Damon18]

Bit late in the day but I fitted a Winterhoff WS3000 Stabiliser Coupling to a caravan a few years back and it was longer (moved the caravan away from the car) by quite a few mm's than the original non stabiliser Alko coupling.
Also it used to be the case that a towball with a longer neck had to be fitted to the bolt on towball type towbars if an Alko stabiliser coupling was used. That meant that the caravan was further away from the towing vehicle.

https://www.ebay.co.uk/itm/Towball-...599624?hash=item20b66dc108:g:tBcAAOSwySVaIYU6

Never too late.
Thanks for your comments and the ebay link.
Unfortunately ours is a VW detachable (unlock & twist to remove) towball so the longer neck won't fit, but will keep it in mind and save as it could be useful for the new towbar we've ordered.
I think the problem seems to more or less linked to the ALKO hitch/handbrake as our car-trailer has an ALKO hitch and it's even worse than the caravan.
Thanks again.

 

[cbdubs]

I have the westfalia detachable tow bar which I think is the one VW fit - if it's not too late for you, I can measure the distance from the bumper to the tow ball if it would help?

 

[B J G]

Never too late.
Thanks for your comments and the ebay link.
Unfortunately ours is a VW detachable (unlock & twist to remove) towball so the longer neck won't fit, but will keep it in mind and save as it could be useful for the new towbar we've ordered.
I think the problem seems to more or less linked to the ALKO hitch/handbrake as our car-trailer has an ALKO hitch and it's even worse than the caravan.
Thanks again.

I have an Ifor Williams little P6 trailer and the tailgate only just clears the coupling handle on that (no handbrake) with a bolt on towball type hitch/towbar you can always use a spacer block between the towball and the towbar.
VW probably wouldn't approve as it increases the towbar mounting loading to the body slightly. More care with caravan noseweight required.

 

[Damon18]

I have the westfalia detachable tow bar which I think is the one VW fit - if it's not too late for you, I can measure the distance from the bumper to the tow ball if it would help?

Hi,
Thanks, it could be useful.
Ours is also a Westfalia detachable, marked "Westfalia 321647" on one side and "$/18 7EO.803.882" on the other.
I measured the distance from the bumper to the centre of the ball and it's about 71/2 cm.
It would be interesting to know if you find the same.
Cheers

 

[Damon18]

I have an Ifor Williams little P6 trailer and the tailgate only just clears the coupling handle on that (no handbrake) with a bolt on towball type hitch/towbar you can always use a spacer block between the towball and the towbar.
VW probably wouldn't approve as it increases the towbar mounting loading to the body slightly. More care with caravan noseweight required.

Thanks.
I've put down a deposit on a bolt on towball hitch through the local VW Commercial dealer (I bought the Cali from them), so hopefully there won't be any problems, but thanks for the heads-up (I anticipate that the load on the towball will be less due to the increased distance, so will reduce my noseweight slightly).
Thanks again.

 

[No_heroes]

Apologies if this is sorted. As the handbrake is offset to the right and the gap is minimal- if you turned the van slightly to the left, creating a small angle between the van and caravan could you sneak it open? Whilst not practical in all situations, that ‘kink’ could mean you can ease the door open with the handbrake button pressed in.

 

[Trebor]

View attachment 34856 View attachment 34857

I have same problem with my Anssems trailers .

 

[Damon18]

Apologies if this is sorted. As the handbrake is offset to the right and the gap is minimal- if you turned the van slightly to the left, creating a small angle between the van and caravan could you sneak it open? Whilst not practical in all situations, that ‘kink’ could mean you can ease the door open with the handbrake button pressed in.

Hi,

Thanks for your input.
You are right, and it would allow us to open the door, but as you say it would not be practical in all situations, and as our caravan is 7,5m long and not easily manoeuvred we decided to replace the tow bar.
We replaced the removable OE with a fixed, and even then we need spacers (see photo).
The problem should be resolved soon as we have ordered a new caravan who’s hitch will allow the door to open (we live and learn).