Simple solution to tailgate breaking problem on 07-08 Tundras- post 1”

[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 1 – You need to go to the hardware store and purchase “push washers” in different sizes. The one that actually fit was the smallest of those displayed. The hole is the size of a BB for a BB gun. Push washers have small slits on them designed to hold tight once forcefully installed. If you find the hole a bit large, just smash the push washer flat a bit with a hammer on a hard surface and test fit. If the push washer hole is too small, lay it on a piece of wood and push the tip of a Phillips screwdriver to open the hole. Remember to FORCE the push washer onto the locking rod for proper installation. These washers can be removed by simultaneously prying them off with two flat screwdrivers.
Photo 2 – Remove tailgate cover by removing the torx screws.
Photo 3 – You will now see the lock. Notice the purple and orange plastic holders. Slide the purple and orange plastic rod holders sideways to remove. These are plastic pieces of caca that break. When they break the rod falls of the locking mechanism and your tailgate no longer opens. You will notice that the same plastic rod holders are also at each end of the tailgate where it latches to the truck bed. I could not get to these and trust they will hold since they only experience sideways movement and not the twisting motion the ones on the handle.
Photo 4 – This is a preview of what you eventually want to do.
Photo 5 – Remove the tailgate handle mechanism by removing two silver bolts. The only remaining thing holding the mechanism in place is a small plastic lip which when depressed causes the locking mechanism to fall right off. I have pointed at the plastic lip with a pen.
Continued on “Simple solution to tailgate breaking problem on 07-08 Tundras- post 2”

[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,

[mrfoster]

I had the same problem with my 1992 C1500. Same design. Same sort of plastic "push in" clips. My "wrap in safety wire" solution didn't look as good but it was a quick and never fail fix.

I like your fix better. My tailgate is apart for some paint repair (garage rash) and I my reassemble with the push washers for a "just in case" fix.

[Strgzr]

Nice work Maximus. I looked at the TSB and my truck is after the affeced VINs... Do you think I need to still accomplish this?

Mike

[mrfoster]

Originally Posted by Strgzr

Nice work Maximus. I looked at the TSB and my truck is after the affeced VINs... Do you think I need to still accomplish this?

Mike

I don't think that this fix has any relationship to the weak tailgate issue that is defined by the affected VIN list. This is another fix to a sometimes occurring problem. Not covered by a TSB - I don't think.

[tundratexan]

Looks like a keeper, thanks much!

[llll1lll1]

Great thread topic. I'll have to do this one soon!

I don't think any 1/2 ton tailgate is happy with 900 lbs on it.

I've seen the cables break with less than that weight on other brands.

Most recently, some folks were putting a Rhino into a long bed GM product out near Barstow. I was watching them thinking "why don't they take the tailgate off?" and BANG! something snapped. The tailgate got tweaked out pretty good. They had to force it to close after that.

Taking the gate off isn't that hard to do. If I'm loading more than 500 lbs or man and machine, I remove it. 20 seconds.

[5.7kingdave]

cookie dough i am a lil confused? do you or do you not like the tundra because last time i checked this was a tundra forum and it sounds like you hate it lol

[waiting tundra]

Originally Posted by 5.7kingdave

cookie dough i am a lil confused? do you or do you not like the tundra because last time i checked this was a tundra forum and it sounds like you hate it lol

Me I luv my tundra, but wtf is going on? I'm glad this mod wuz posted, cause once I didn't like the way my tailgate opened and after reading a similiar thread Investigated my tailgate. Didn't want to drill small rods, like push washer solution much better. On my to do list. I don't stand on my tailgate ,drive atv on them or abuse mine much at all. In fact it's just a grocery getter & a hurricane evacuation vehicle FOR NOW. Guess what KINGDAVE one of these days it's gonna be my work truck, & I thank the penhead that designed my tailgate should go back to penhead school. No problems I'll beef it up myself, fix the latches, change the radio along w/a few other mods then we'll see what toyota's got. Nuthen wrong w/bitshin bout short cummins, what can't stand on a tailgate & load the bed in a work truck? Da ya ever really used a work truck for work? Course don't fill to bad ,cause I've personaly destroyed many tailgates on many trucks over the years. All the ford tailgates at the plant I work at don't work, but I promise the tundra tailgates wouldn't last long either. They going in the right direction, but they gonna have to beef up a few thangs if they want the work truck market.

[lwfabs]

Great thread topic. I'll have to do this one soon!

[SE2000]

Those plastic clips have been around for decades. they don't rust and are smother operating but being plastic, they are more prone to breakage. For a different idea, those plastic clips are available in metal that may be easier to retrofit.
It might be wise for us to push in on any tailgate that has a lot of pressure on it

[augustus88]

Thanks for the step-by-step tutorial. Had some spare time so I did this mod as a precaution a few days ago. I did a couple of things a bit differently. I didn't remove the tailgate handle mechanism. I was able to remove one rod end and plastic holder at a time with everything else in place. I trimmed the plastic piece and installed a push washer as described. I was also able to do this with all four plastic holders including the two at both ends of the tailgate. I found small needle nose pliers made removing the clips on the ends possible. You can use the pliers to push the washers on too. Open the pliers so the rod fits between the jaws. Lay a push washer on the side of the needle nose jaws toward the tip. Slide the pliers/washer under the rod and push up. The plier's jaws will put even pressure on both sides of the washer like you did with the two screw drivers. This allowed me to do the whole job in place without removing anything but one rod end at a time.

[Tankerhank]

Originally Posted by SE2000

Those plastic clips have been around for decades. they don't rust and are smother operating but being plastic, they are more prone to breakage. For a different idea, those plastic clips are available in metal that may be easier to retrofit.
It might be wise for us to push in on any tailgate that has a lot of pressure on it

Yup, I believe Ace Is The Place carries those clips in metal... in my favorite aisle.