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Install | Door Struts

Step-by-Step Instructions for Installing Stop Stay Rear Door Struts on Your Sprinter Van

Step 1: Gather tools

    Step 2: Mark the Door Brackets

    • Identify the brackets labeled "D" and "P" for the driver and passenger sides of your Sprinter Van.
    • Take the driver-side bracket and position it where the door's strut will be mounted.
    • Use a Sharpie to mark around the hinge areas on the door to keep the bracket aligned when reinstalling.
    • Make sure to mark both the top and side of the hinge.

    Step 3: Remove the Door Bolts

    • Using the T30 Torx bit, remove the screws from the marked locations on the door of your Sprinter Van.
    • Keep the screws handy as they will be reused to attach the bracket.

    Step 4: Install the Brackets Loosely

    • Attach the driver-side bracket (marked "D") loosely with the screws you just removed. This will allow some play for alignment adjustments.
    • Do not tighten the screws all the way yet, as the bracket needs to self-center when the door closes.

    Step 5: Align the Bracket

    • Close the door of your Sprinter Van to ensure that the bracket aligns properly with the pin.
    • The pin should enter the bracket without any resistance. If necessary, adjust the bracket by shifting it slightly before tightening the screws completely.

    Step 6: Remove the Plastic Rail Covers

    • On the door frame of your Sprinter Van, locate the small plastic rail covers (which resemble small railroad spikes).
    • Use a small Phillips or flathead screwdriver to lift them out carefully.
    • If your van has a screen installed (like in a Revel model), remove the screen using a Phillips screwdriver.

    Step 7: Prepare the Rear Door for Cutting

    • After removing the plastic covers, you will need to cut a section of the rear deck to fit the bracket plate.
    • Use painters tape and a Sharpie to mark the section you need to cut. The plate should fit just over the edge of the cut-out area.
    • Once marked, use a jigsaw or air saw to carefully cut out the section.

    Step 8: Clean Up the Cut

    • After cutting, clean up the edges with a razor blade or file to smooth out any rough parts.

    Step 9: Reassemble the Panel

    • After cleaning the cut area, reattach the plastic rail covers and ensure they fit snugly.
    • Press the pegs back into their slots to secure the panel in place.

    Step 10: Mark and Drill Holes for the Plate

    • Position the plate over the newly cut section and align it with the holes in the Sprinter Van door.
    • Mark the locations for drilling with a Sharpie or center punch.
    • Once marked, drill the holes using the drill bit provided in the kit.

    Step 11: Use a Step Bit to Enlarge the Holes

    • Enlarge the drilled holes using a step bit. This will create a perfect size for installing the Rivnuts.

    Step 12: Apply Rust Prevention

    • Spray the drilled holes with Rustoleum rust reformer to prevent rust from forming in the exposed metal.

    Step 13: Install the Rivnuts

    • Use a Rivnut gun to install the Rivnuts in the drilled holes. This will allow you to securely attach the struts without needing access to the back of the panel.
    • If you're using a manual Rivnut gun, tighten the Rivnuts by threading them in and squeezing the handles until snug.

    Step 14: Attach the Ball Mounts

    • Install the ball mounts on the driver-side and passenger-side doors of your Sprinter Van.
    • Place the thick black washer under the ball mount, then secure it with the Nylock nut. Use a half-inch wrench to tighten the ball mounts.
    • Be careful not to overtighten as the Nylock nut will prevent it from loosening.

    Step 15: Attach the Struts

    • With the brackets and ball mounts in place, attach the stop stay struts to your Sprinter Van.
    • Each strut will have a small retaining clip that secures the strut onto the ball mount. Remove the clip, attach the strut to the ball, and then replace the clip to lock it in place.

    Step 16: Final Adjustments

    • Ensure the struts are properly aligned and that the door opens and closes smoothly.
    • Check the struts and brackets to ensure there is no play, and all components are securely fastened.

    Step 17: Test the Doors

    • Close and open the rear doors of your Sprinter Van to make sure the struts are functioning as intended.
    • The doors should open smoothly and stay in place without slamming shut.

    Congrats on installing your new gear from Owl!

    Remember, Owl is the #1 manufacturer of Off Road gear and accessories for Adventure vans. We have our van experts standing by at our HQ in Arizona if you have any questions. Our gear for Mercedes Sprinter vans, Ford Transit and Winnebago Revel is Made in the USA, and many products are in stock and ship fast.

    More soon,
    John Willenborg