Tailgate O.JPG 3003 hits | 87.28 KB | Posted: 11/28/04 If the motor spins but won't move the glass, just push it down all the way, and you can open the tai...
End Seal.JPG 3201 hits | 116.55 KB | Posted: 7/7/03 If you only need to change the weatherbelts, or if the glass needs to come out, remove the screw fro...
Weatherbelt.JPG 2897 hits | 96.51 KB | Posted: 7/7/03 Use a screwdriver to gently pry the OUTER weatherbelt up just enough to pop the cllps loose. I've p...
Weatherbelts.JPG 2320 hits | 31.64 KB | Posted: 11/28/04 This outer weatherbelt has begun to dry rot, and is already leaking water into the unpainted interio...
Tailgate I.JPG 2654 hits | 81.05 KB | Posted: 11/28/04 The wetness on the moisture barrier shows that the weatherbelts are dry-rotted & should be replaced ...
Tailgate.JPG 3671 hits | 118.84 KB | Posted: 7/7/03 This can be done with the tailgate open or closed. After removing the inside access panel, remove t...
Glass Up.JPG 2770 hits | 72.74 KB | Posted: 11/28/04 If the motor doesn't work, push the glass up for access. The glass is strong enough to support its ...
Mechanism.JPG 3068 hits | 82.01 KB | Posted: 7/7/03 The 3 black bolts hold the center latch control and are used to align it so the latches open at the ...
Glass.JPG 3886 hits | 106.83 KB | Posted: 7/14/03 If the window switches work, the L latch must be fully closed to defeat the safety interlock switch....
CenterMech.JPG 1121 hits | 51.45 KB | Posted: 5/17/07 Center mechanism front & back.
The rubber grommet for the handle operating rod is slid onto that ...
Inside L.JPG 2722 hits | 44.04 KB | Posted: 11/28/04 This is the optimum location for the glass since you have access to all the fasteners to remove the ...
Inside R.JPG 2195 hits | 35.22 KB | Posted: 11/28/04 The nuts for the glass track are under this fixed support, but the bolts for the regulator will be a...
Inside C.JPG 2512 hits | 44.59 KB | Posted: 11/28/04 If you cant open the t/g, remove the inside access panel & pull these 2 rods inward. Either unclip ...
Mechanism Inside.JPG 2871 hits | 82.57 KB | Posted: 7/7/03 The rod running to the Left (down) is the interlock rod that detects the glass being fully down. It...
TGRegulator.JPG 1233 hits | 60.58 KB | Posted: 5/17/07 Tailgate Window Regulator front & back
If EITHER the glass or the motor is installed, the regulat...
Mechanism Side.JPG 2032 hits | 55.57 KB | Posted: 11/28/04 View from the passenger side with the t/g lowered.
RodClips.jpg 1942 hits | 27.44 KB | Posted: 11/28/04 To release the rods, push the hook end of the clip off the rod, then pull the rod down out of the cl...
Center Bolts.JPG 1954 hits | 46.65 KB | Posted: 11/28/04 Mark the bolt locations, even if you plan to move the latch later. It gives you a reference point.
Center Gone.JPG 1980 hits | 55.31 KB | Posted: 11/28/04 To access the motor connector, push out these 2 retainers and pull the connector where you can see i...
Center Mechanism.JPG 2050 hits | 54.24 KB | Posted: 11/28/04 The center mechanism
Center Bent.JPG 2021 hits | 29.6 KB | Posted: 11/28/04 This is why the inside handle doesn't sit flat. If someone pulls the handle before the glass is ful...
Center Interlock.JPG 1929 hits | 60.26 KB | Posted: 11/28/04 The numbers show the sequence of events for PROPER operation of the inside latch handle. 5 & 6 shou...
Center Straight.JPG 1688 hits | 25.77 KB | Posted: 11/28/04 Fortunately, with the mechanism out, it's easy to straighten the bent lever. Spray it with protecti...
Latch Closed.JPG 1901 hits | 35.98 KB | Posted: 11/28/04 To operate the motor with the tailgate open, simply close the driver's latch. Be SURE to open it be...
Latch & Switch.JPG 2040 hits | 68.04 KB | Posted: 11/28/04 This is the switch on the driver's latch that prevents the motor from operating with the tailgate op...
Mechanism All.JPG 1881 hits | 73.53 KB | Posted: 11/28/04 This shows the inhibit switch installed in its early location on the center mechanism ONLY for illus...
Motor Bolts.JPG 1903 hits | 41.51 KB | Posted: 11/29/04 To access the motor, remove these 3 bolts with an 8mm or 5/16" socket. If the glass has already bee...
Wire Unclipped.JPG 1811 hits | 36.81 KB | Posted: 11/29/04 To get enough slack in the wire to pull the motor out & work on it, remove the clip from the bottom ...
Motor Open.JPG 2086 hits | 54.99 KB | Posted: 11/29/04 To change or repair the motor drive gear, remove the phillips screw and then the seal plate to expos...
Window Motor Gear.jpg 2180 hits | 48.91 KB | Posted: 11/29/04 This is the repair kit, but you can also use 1/4" fuel hose with thin plastic tubing inside to reinf...
Motor Apart.JPG 2121 hits | 69.52 KB | Posted: 11/29/04 The pointers show the rubber insulators. The metal & nylon gears simply slide up off the shaft. Th...
Regulator.JPG 1837 hits | 58.74 KB | Posted: 11/29/04 The motor drive's shaft aligns thru the hole in the top of the regulator. If the large gear is poppi...
Swingaway Brace.JPG 1656 hits | 71.44 KB | Posted: 11/29/04 Before removing the regluator, remove the tire carrier's strike brace (if equipped).
Strike Bracket.JPG 1606 hits | 67.45 KB | Posted: 11/29/04 Later Broncos (~'90-96) have 3 bolts holding the strike to the bracket. Before that, there were onl...
'78-82 is only different in the interlock switch...
Regulator Remove.JPG 1563 hits | 82.08 KB | Posted: 11/29/04 With the regulator arms in this position, all the mounting bolts can be accessed & removed.
Regulator Out.JPG 1529 hits | 68.47 KB | Posted: 11/29/04 The regulator fits out the driver's side. On earlier Broncos, there is a brace here that must be re...
Trim Panel.JPG 1833 hits | 80.72 KB | Posted: 11/29/04 The trim panel can be removed after the access panel if the glass is rolled up out of the way. No o...
Switch C.JPG 1556 hits | 56.71 KB | Posted: 11/29/04 The tailgate key switch is 2 micro SPDT switches riveted into a bracket, and operated by a paddle at...
Switch Down.JPG 1479 hits | 47.95 KB | Posted: 11/29/04 When the key is rotated CW, the paddle presses the lower switch. The silver hairpin clip retains th...
Switch Up.JPG 1423 hits | 62.88 KB | Posted: 11/29/04 When the key is rotated CCW, the paddle presses the upper switch. Note the arrangement of parts on ...
Pad.JPG 637 hits | 60.08 KB | Posted: 5/17/07 This pad is used to protect the tailgate paint from the rubber bumper on the bottom of the swingaway...
Switch Off.jpg 1402 hits | 15.51 KB | Posted: 11/29/04 By removing ONLY the silver clip, the switch assembly can be removed from the lock cylinder.
The parts might be OUT of factory order, but they'll st...
Clip Remove.JPG 1354 hits | 62.56 KB | Posted: 11/29/04 To remove these clips (which are used on the frame also), push the pin in the center all the way out...
Clip.JPG 1184 hits | 99.79 KB | Posted: 11/29/04 With the clip off, the tailgate support cables can be removed.
Tailgate cables.JPG 1237 hits | 59.56 KB | Posted: 11/29/04 Early cable screws are #3 phillips; later ones are T-50. New cables are available from most parts s...
Torque Rod.JPG 1578 hits | 79.06 KB | Posted: 11/29/04 Before unbolting the tailgate from its hinges, first relieve the torque rod by bracing it against th...
StrikeBolt 78Bronco.jpg 1465 hits | 56.08 KB | Posted: 11/29/04 '78-82 Broncos used this type of strike bolt, and a different latch from '83-96. They are not inter...
Tailgate Torsion 8396.jpg 1495 hits | 79.58 KB | Posted: 10/16/05 Hinges, Torque Rod, & '83-96 Strikes. The strike bolt is the only thing in this diagram specific to...
Tailgate Torsion 7882.jpg 1579 hits | 59.41 KB | Posted: 11/29/04 78-82 Strikes & Torque Rod. The strike bolt is the only thing in this diagram specific to '78-82. ...
92s.JPG 1251 hits | 72.44 KB | Posted: 11/10/05 Some tailgates split here on the R side at the top. I think it's due to collision since I've never ...
FenderBrace.JPG 1069 hits | 61.01 KB | Posted: 4/1/06 The swingaway brace inside the R quarter panel is spot-welded & riveted into place.
TGSwitchC274.JPG 849 hits | 36.71 KB | Posted: 4/26/07 Pinout for '87-96 Dash Switch CONNECTOR for Tailgate Window (looking into the switch, the pins are r...
1 Clip 382929-S
2 Link 43868
3 Bumper 44482
4 Nut and Washer Ass...
TGTorqueRodBrkt.JPG 549 hits | 58.28 KB | Posted: 9/12/07 The infamous torsion bar bracket. It cups up, so if it's allowed to collect dirt & rain, it rusts o...
The tailgate must be removed to get the torsion bar in or out.
TGWiring96.JPG 499 hits | 53.95 KB | Posted: 9/12/07 Note that there is no connector near the ground wire, which is forward of the L taillight. C418 is ...
C418.JPG 512 hits | 66.26 KB | Posted: 9/12/07 This is all the wiring for the tailgate, except the ground for the defrost grid. This connector is ...
Tailgate Tech
