What Kind of Electric Tailgate Strut Is Suitable for an Overland SUV?

Overland SUVs often carry additional tailgate-mounted equipment, including storage systems, ladders, spare-wheel accessories and camping equipment.

These modifications can increase tailgate weight, change its center of gravity and place additional stress on the factory power liftgate system.

The Short Answer

A suitable electric tailgate strut for an overland SUV must provide sufficient operating force while maintaining structural strength, controlled movement and reliable performance under vibration, temperature changes and uneven vehicle angles.

High force alone does not make a strut suitable. The complete system must match the modified vehicle and pass vehicle-level validation.

Why Can OEM Power Liftgate Struts Become Insufficient?

OEM struts are designed around the original tailgate weight, balance and installation geometry.

After accessories are added, the power liftgate may:

• Open or close slowly

• Stop or reverse unexpectedly

• Fail to hold its position

• Require excessive motor current

• Overload gears, hinges or mounting brackets

• Become unstable when the vehicle is parked on a slope

The required force depends on both the added weight and its distance from the tailgate hinges.

Example: Heavy-Duty Honda CR-V Electric Tailgate Strut

For one TOMASTER Honda CR-V power-tailgate-strut configuration, the tested design specifications include:

These values apply to a specific product configuration and test method. They should not be treated as universal requirements for every Honda CR-V or overland vehicle.
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Which Performance Areas Matter Most?

1. Correct Force and Motor Selection

Spring force must support the modified tailgate without making closing difficult. Motor torque must provide controlled movement without repeatedly operating near stall conditions.

Stall torque is useful for evaluating maximum motor capability, but rated operating torque, current consumption and thermal protection are also essential.

2. Structural Load Capacity

The strut must resist axial pulling forces and radial loads created by vibration, body movement and imperfect alignment.

In this example, the strut assembly remained intact during a tensile-resistance test above 6,000 N and a 500 N radial-load test at the sleeve connection.

These component tests reduce structural-failure risk but do not replace validation of the vehicle hinges, brackets and mounting points.

3. Impact and Noise Performance

Drop testing helps identify loosened internal parts, housing damage and changes in operating noise following impact.

After the specified drop-test procedure, the evaluated strut showed no visible surface damage, abnormal operating sound or noise-level variation greater than 5 dB(A).

The drop height, orientation, surface, sample quantity and acceptance criteria should be documented in the project test report.

4. Temperature Durability

Overland vehicles may operate in hot deserts, cold regions and changing climates.

The evaluated strut configuration completed separate durability tests at normal temperature, 80°C and −30°C. Testing at temperature extremes helps assess motor performance, lubrication, seals and internal transmission stability.

5. Vehicle-Level Validation

Before production approval, the complete system should be tested on the modified vehicle for:

• Opening and closing cycles

• Hold-position stability

• Operation on slopes

• Obstacle detection and anti-pinch response

• Manual emergency operation

• Motor current and temperature

• Hinge and bracket loading

• Dust, water and vibration exposure

• Latch engagement and height-memory functions

How Should Buyers Select an Overland Tailgate Strut?

Before selecting or customizing a system, provide:

• Vehicle model and production year

• Complete modified tailgate weight

• Accessory weight and mounting position

• Tailgate center of gravity

• OE strut dimensions and mounting coordinates

• Required opening angle and speed

• Temperature and environmental requirements

• Target durability cycles

• Electrical and controller requirements

TOMASTER develops customized electric tailgate systems for overland, modified, armored and heavy-duty vehicles. Final selection is based on measured vehicle data and complete-system validation rather than individual headline specifications.