Rear tailgate replacement?

Hi all, due to a faulty/wornout rear window seal, the tailgate has rusted out in spots on the new aquisition.

When I bought it, the previous owner have us a new tailgate "shell". How crazy is it to replace this outer shell? And what is envolved with getting all of the internal pieces in/out and working?

Sorry if this is posted somewhere already, just getting accustomed to the UI and not seeing a search option.

Thanks, Marshall

One of our FSB tech. responders is a bit under the weather.., that's why you're not gett'n

answers to your issues. Bear with us.., he'll be back soon.

Hey Marshal,

If you have the old tailgate, it should be a matter of transferring parts over. Take your time and lots of pics during the process. It's a nut and bolt thing.

Good luck 

Window seals are not the cause, the tailgate has holes to let out what water gets in from rain or washing.  The cause is that the skin to frame seal has never in the history of Broncos been properly done.  The holes that are supposed to drin the gate are higher than the lowest part of the gate thus allowing water to set against the skin and frame surfaces.

Before you start, fill the bottom edge where the skin wraps onto the frame with POR15 or similar product.  They never seal that properly and that is the cause of the skin rust out on the bottom of tailgates.  What ever product you use, don't get it on you or you will be wearing it till it wears off naturally. 

Second, be very carefull of taking the old tailgate off.  The torsion rod that assists in handeling the heavy gate is a Bear trap, it can break bones or seriously damage your hand if not done properly. I've seen it happen.  To release it safely, just crack open the tailgate far enough to get at the retainer clamp on the right end of the gate. Keep the gate in the upright position while removing the two bolts, it will still snap a little so keep your hands out of the way when the retainer comes off.  Do the same when remounting the tailgate.

You need to remove the end seals from the gate to get the window out.  Order a complete new set of seals, the ones along the length of the window will usually bend and be destroyed in the removal process.  You might get away with salvaging them if extreemly carefull, but new ones are probably needed anyway.

Once the seals are removed the window detaches via 4 nuts on the lifter bars.

Check here for seals, it also gives you a pretty good idea of what is inside the gate http://lmctruck.com/icatalog/fd/full.aspx?Page=23

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So then the latch control arm just hangs and gets pushed down by the window? Looking at the schematic there and it looks like that literally just hangs there and the window glass hits it on it's way down? Just doesn't seem right

Yo 94,

No one that I know has a pic of the  "clip" .

[SIZE=14.4px]A friend of mine jury rigged a replacement clip,  but never snapped a pic of it.[/SIZE]

[SIZE=14.4px]Ask at a Ford dealership parts section.  Show them the attached Bronco Graveyard diagram showing a depiction of the clip..[/SIZE]


 


 

The tailgate Vertical interlock "rod assembly" guide clip snaps into the "Lower Torsion Bar Bracket" and upper part connects to Control Mechanism, aka Center Mechanism, . It "jams" the inside handle until the glass is all the way down. This bracket is bolted on.

See how BikerPepe` "Also a good time to consider removing the "window down" safety feature...  fixed it by securing the center mechanism 

Removing the L bracket and the rod... eliminates the safety feature  If you choose to go that route... you need to be mindful that dropping the tailgate with the window still raised enough to contact the edge of the gate, can easily shatter the glass and potentially cause inury, or at least a considerable mess and major hassle, replacing said glass/defroster/etc. Handle according to your ability, confidence and that of others you may let use your rig.That said... removing the L bracket is easy. I simply took a grinder to the rear of the rivet at the center of the L bracket, on the back side.Once you've done that... no need to install the safety catch rod (or a place to put it, for that matter) and you might be able to re-use that same rod keeper, plastic clip... if it's in better shape than one you're keeping in service. If not... I've seen them available somewhere but have no idea to link you.

This is the lever to remove if you want to delete the "window down" safety feature...

passed" it by deleting the "window down" safety feature...

This is the lever to remove if you want to delete the "window down" safety feature...

See the two attachments below.  

Go through http://www.supermotors.net/clubs/superford/registry/2742/12689-2

For a vg good collection of Big Bronco tailgate tech by Steve.