Tailgate Walkthrough
Home Up

 

Table of Contents

 
· Bronco Tailgate Instructions
·

· Open tailgate and remove inner panel to access interior of the tailgate

· Snap latches shut so you can key the motor and get the window out.

· The following is the easiest way I found to get your window out so you can do a good job of retrieving the window inside and outside gaskets. Also when assembling with new gaskets you can put the seals in first and slide the window afterwards.

· Protect the window and grind off 4 rivets at the bottom of the window

 

remove all bolts. There is a hole in the gear to access one bolt.
· Remove motor assembly out on left side and pay attention to how wires are routed to clear the window mechanism and window itself. You have to get this right when you reassemble the motor etc.

· Remove window guides 2 bolts on each on the side panels

· Left side has a clip for the wiring harness, mark this guide to reassemble the same . Disconnect right side rod to latch at center mechanism by lifting out of bushing and twisting.

· Unscrew 3 screws from right side latch and remove.

· Remove inside latch pull 2 screws.

· Remove pivot assembly at center of gate ,3 bolts, and disconnect wires at loom;

Remove guide/clip with all Note picture.
· Remove cam lock on left side by 2 ea. clips Note picture.

· Disconnect wires by removing left tail light and unsnapping connector.

· Then feed through gromment at qtr panel gromment on gate side.

· Loosen 2 bolts on right side , then

close tailgate enough to take the spring pressure off.

· Remove the limit straps at the body and unbolt the hinges.

· Now remove the limit straps from the tailgate

· INSTALLING THE FIBERGLASS TAILGATE!

· A die grinder , drill and some hand files will be helpful tools to have for machining the various holes and slots in the following steps.

· Cut the two slots out on the bottom for the window bumpers , install bumpers from old tailgate. These have to be stretched

through so if they are tight use some lube.
· Drill out drain holes and finish to size. you should be getting good now.

· Neatly drill out and finish fit slotted holes on bottom for hinge plates. These holes are slotted to allow for adjustments from left to right when installing the tailgate.

· Hinge plates should be made with 2 3/8 wide by 5 inch long steel 1/8" thick, weld 3/8 coarse nuts in the correct pattern for the hinge making sure to have a left and right, this way the hinge , tailgate, and hinge nut plate sandwich together for a tight fit and strength.

· Drill inside panel for latch handle, pivot bracket , and wire loom fasteners.

· Holes for the pivot bracket will be large for adjustment purposes.

· At this point I think if you hang the tailgate on the hinges and hookup the cable straps, you can finish the work with your bronco holding the tailgate rather than the tailgate rocking around on your bench. Just a suggestion so we will proceed that way.

· Make sure you have loosend the hinges on the sides inside the

  tailights for adustments.
· Note: The above proceedure may not have to be done on your bronco.

· Install limit straps to tailgate using the nut plate provided in hardware kit. It will be 2"

  square, Install limit cables on each side of the body. I would rough adjust the hinges to the opening at this time

· Drill mounting holes through inner panel for regulator to bolt

· Install window regulator making sure to have wire looms underneath

· using straps with weld nuts is the best mounting here. These are included in hardware kits.

· Drill out hole for key switch and using a file and taking time here fit for the exact hole needed. We want a nice tight fit for the key assembly!

· Drill inside panel for latch handle, pivot bracket , and wire loom fasteners.

· Holes for the pivot bracket will be large for adjustment purposes.

· At this point I think if you hang the tailgate on the hinges and hookup the cable straps, you can finish the work with your bronco holding the tailgate rather than the tailgate rocking around on your bench. Just a suggestion so we will proceed that way.

· Make sure you have loosend the hinges on the sides inside the tailights for adustments.

· Install tailgate onto the hinges using hinge plates in hardware kit. Snug into position .

· Now is the time to check adjustment. On mine i needed shims on one side to raise the tailgate.

· Also i had to change the adjustment on the left stricker to allow for an additional 1/8" up.

· To do this if you need to bend one side of the nut plate trap I call it , this is inside the tailight.

· With a little finesse you can get the nut plate out and grind off the top edge 1/8".

· Note: The above proceedure may not have to be done on your bronco.

· Install limit straps to tailgate using the nut plate provided in hardware kit. It will be 2" square, Install limit cables on each side of the body. I would rough adjust the hinges to the opening at this time

· Drill mounting holes through inner panel for regulator to bolt

· Install window regulator making sure to have wire looms underneath

· using straps with weld nuts is the best mounting here. These are included in hardware kits.

· Drill out hole for key switch and using a file and taking time here fit for the exact hole needed. We want a nice tight fit for the key assembly!

· Check fit of retainer clip to key lock before installation.

· Due to the extra thickness of the sides we found it necessary to shorten the latch rods 1/4". They are not adjustable and have to be the correct length to work properly.

· You will need to cut a 1/4"out and weld these back together in the same position as before.

· Install handle with short strap nut plate sandwiched and bolted together, finish attaching rods.

· Install latch strikes, pivot plate , and latch rods. Connect handle rod and

lower rod to pivot assembly. The lower rod has to be bent to contact window in the down
position and allow latch release mechanism to function. Adjust pivot mechanism until both latches release at the same time! Check operation.

· Install window felts now , be careful with the clips as they bite.

· Install electric loom through left side of tailgate and into left tailight.

· Window guides need to be modified, they are too tight to the window. looking at how they are mounted , shorten each mounting stand about an 1/8" inch ,

· you will have to cut and weld these so take your time and do it neatly. The fiberglass tailgate sides are thicker than the original tailgate sheetmetal , this caused my

  window to fit too tight between the tracks so shortening the guides solves the problem. The window must slide smooth and easy for the motor to operate correctly.

· Install window guides, Remember! left side window guide has a retainer for the wiring loom.

· Align top of window guide to window slot in tailgate.

· Install window by sliding between inside and outside window felts.

· Install window mechanism guides onto arms of the motor lift assembly.

· Install plastic washers back onto window bottom , line up with lift brackets ,

· Bolt back together with 1/4" x 1 1/4" bolts and nilox nuts.

· Remember, these are replacing the rivets so don't overtighten, the nilox nuts will not loosen. Assembling the window this way will allow you to install the felts with the window out. The window slips between the felts without the bottom piece attached. I like trying

  to make it easier to work on for the
  future mechanic , (which usually is me)

· Make sure the rod from the pivot assembly contacts the bottom of the window properly, This is what actuates the mechanism to allow the latches to unsnap and open the tailgate.

· Work the window in and out a few times to make sure it is adjusted correctly and does not bind in the tracks. Then shut the gate and check the window going up into the roof section for fit. The way the window guides adjust on the side has a lot to do with the way the window slides up. Take your time here and try to get the window moving

  as smooth as possible. Motors are expensive and the clutches wear out under unusual pressure from window guides. After you know the tailgate is adusted correctly and everything fits right, it is time to take it apart for painting. I had to drive mine around some first because I was burned out from working on it!
The above sketches show the brackets of the hardware kit. Use the following measurements. For the A bracket cut 1/8" x 1" strap 7and 11/16" long with hole centers 6and 11/16" apart , punch holes with 9/32 punch and weld 1/4" coarse nuts onto one side. A bracket is for the right side motor mount. 1" long bolts are needed with uss washers on the A B and C brackets, For the B bracket cut the same strap 6and 5/16" long with 2 holes 5and 5/16" apart. Measure 1/2" in from each end for correct hole location. The B bracket is for the left side of the motor mount. For the C bracket cut the same strap 3 1/2" long , measure in 1/2" from each end and punch holes. 1/4" nuts are welded on one side of this bracket as well as A and B. The C bracket is used behind the center inside pull handle. The 2 square brackets are cut from 2" strap with a 7/16" hole punched in the center and 7/16" uss nut welded on one side. These 2 brackets are for the limit cable mounts on each side of the tailgate. The bottom plates with 3 holes each are for the hinge mounts. They go on the inside and sandwich the tailgate and hinge together for strength. The slotted holes you fit on the bottom of the tailgate allow for hinge adjustment. Three 3/8" coarse nuts are welded on one side of each bracket in such a way to make a left and right hand part. One of each necessary for the hinge mounts. These hinge plates are made from our templates and the welder determines left and right when locating the weld nuts. The dimensions are 2 1/2" x 5 1/2" and they are cut from 3/16" steel.

BACK TO TOP

Send E-mail to john@autofab.com with questions or comments about this web site.
Last modified: March 19, 2009