[Maximus 2]

After reading the numerous threads reporting the unpredictable problem of 07-08 Tundra tailgates failing to open, I decided to be proactive and address the problem before it happens. With my luck, it will happen when I have a ton of gravel to unload at a job site. This is one of the links reporting this problem : http://www.tundrasolutions.com/forums/tundra/116509-tailgate-handle-is-broken-again/
I will post the procedure in two threads titled “Simple solution to tailgate breaking problem on 07-08 Tundras- post 1” and “Simple solution to tailgate breaking problem on 07-08 Tundras- post 2” I apologize for not knowing how to post large photos of the procedure. Instead all I could do is post thumbnails. ** By the way, this method of holding rods in place is commonly found on older cars with manual door locks. I guess Toyota did not want to adhere to the tried, simple, and true. Instead they probably spent thousands on research and development to come up with “PLASTIC” holders. If anyone knows how to post this thread on the DIY blog, please do so for me.

Photo 6 – In order to properly secure the push washers, I opted to remove the purple and orange plastic holders by squeezing the end and pushing up. Work on one at a time.
Photo 7 – Once the plastic holder has been removed, trim off a little bit go give the push washer more to hold onto. Be careful not to trim up to the locking groove on the plastic holder. If you do, the plastic holder will no longer lock into the locking mechanism. On trimmed, reinstall plastic holders onto the locking mechanism and re-install the lock on the tailgate as you found it when you first removed the cover.
Photo 8 – Install the rod into the plastic holder and slide the holder onto the rod until it locks. Using both hands, test fit the push washer by forcing the washer onto the rod. If the hold is too big, smash it flat with a hammer and retest, if the hole is too small, lay the washer flat on a piece of wood and force the tip of a Phillips screwdriver to expand the hole.
Photo 9 – Due to limited space, I had a much more difficult time installing the push washer onto the orange plastic holder. I finally succeeded by suspending the push washer between two flat screwdrivers and forcing the push washer onto the rod using both screwdrivers at the same time.
This just about guarantees that even if the plastic holders break in the future, the rods will not pop out of the mechanism and thus avoiding the problem all together. It is insulting that we consumers have to rely on each other to fix some ding bat engineers short sightedness.
Laters,