The three nylon bushings inside the motor are a common source of failure.  These bushings are driven by a worm drive and are what makes the outer gear rotate.  I have heard of replacing them with ball bearings or some dowels wrapped in fuel line of the right size.

Now you can remove all the linkages and latches.  Each latch and the handle are held on by two bolts.  The linkages are all connected to a central bracket and are held on by yellow clips.  This picture shows how they are all connected together.

The next step is to remove the bracket holding the torsion bar to the body.  Take extreme care here as the bar packs a lot of force.  I recommend trying to remove the bracket while the tailgate is as closed as possible to relieve pressure on the bar.  I was foolish enough to do it with the tailgate down.  Both bolts broke off allowing the bar to snap back and sent the bracket off to never-never land.  I was never able to find the bracket so I had to get another one.

The only things left inside the tailgate are the two window runners, each is held on by two bolts.  On one of my runners, a mount was rusted off as shown in the picture.  This allowed the window to sit crooked in the tailgate and did not allow it to slide up and down easily.

This picture shows my Macguyver method of fixing the bracket.  There is enough play in the mounting points on the tailgate to allow adjustments to the runners to compensate for any irregularities.

The last things to do before removing the tailgate are to disconnect the support cables and to unbolt the three bolts going into the tailgate on each hinge.  You should now be able to pull the tailgate loose and transfer anything left into your new tailgate.  Reverse the whole process to install your new tailgate.

Be very careful when reattaching the glass to the brackets.  While tightening the bolts down, somehow one of them was crooked and allowed the nut to put pressure on a very small area and ended up shattering the whole thing.  Cleaning up the glass takes a long time!

This shows what my new tailgate looks like.  There is a bungee cord holding my tire carrier because I haven't put the latch bracket back on by the time I took the picture.  I didn't put the silver vanity panel back on because I didn't want to drill new holes for the mounting studs.  One thing I would like to mention is that I coated the entire inside of my new tailgate with rubberized undercoating to prevent any rust.

Off Road T rucks

Page last updated on October 18th, 1999