Thanks - just to clarify the noise is not a rattling. The main catch in the upper tailgate instead of clicking once is clicking twice if I press the key or dash button to release the tailgate which then remains locked or sometimes half closed. This indicated the 2 rubbers needed turning anticlockwise as the upper tailgate was not seperating from the lower tailgate. I've unwound them to an extent that the upper taligate was caused to sit proud of the rear quarter panels and the trunk lights stayed on - even then it failed to rectify it as did lowest settings.

I thought I sussed it out this afternoon when I realised the lower tailgate right side fixed latch is not always locking in place as i could pull slightly on the taligate on this side and not the left. I pushed it home and felt it lock home and repeated my testing - only to find it double clicking again when I hadn't reopened the boot.

Now here is where I am confused...............with the tailgate upper section when I repeatedly use my fingers to push the centre upper catch in and then depress the key fob button it opens the catch every time without fail so I know the electronic actiator/motor switch is working fine and so is the catch mechanism in so far as it's ability to open. I have visually inspected for signs of damage - perhaps resulting in a misalingnment issue requiring a new unit but it seems fine.

Driving me nuts - main dealer has car tomorrow for other work, (new bmw replacement screen fitted by RAC a couple of weeks ago and needs to go in due to rain sensor wipers not working), anyway I have asked them to look at the trunk/boot/tailgate issue although I have told them I have already spent hours trying to diagnose same !

I need professional help !

Thanks guys - any more comments really appreciated & especially from anyone else who has knowledge or experience of exactly the same problem.

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Black & Black E53 X5 2002 4.4i Sport