Hammer Built - Built to Hammer On: Modular Tailgate Reinforcement System

[flip]

Tailgate Alignment
Inspection

NOTE: Removal steps in this procedure may contain installation details.

1. Check tailgate-to-body dimensions.

Adjustment

All alignments

1. Remove the nuts and the spares wheel.
   Torque: 41 lb.ft (55 Nm)

1. Open the tailgate about 5 to 10 degrees.

1. Note down the movement in tailgate due to spare wheel removal. Noted movement due to tire weight should be accounted during final alignment.

Tailgate left and right, up and down alignment

1. Remove the RH rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).

1. Open the tailgate.

1. 1. Remove the bump stop.
2. 1. Remove the bolts and the striker.
3. 1. Loosen the bolts.
      Loosen:
      : 2 turn(s)

1. Loosen the bolts.
   Loosen:
   : 2 turn(s)

1. Adjust the tailgate as required.

1. Tighten the bolts.
   Torque: 30 lb.ft (40 Nm)

1. Open the tailgate.

1. 1. Tighten the bolts.
      Torque: 17 lb.ft (23 Nm)
2. 1. Install the striker and the bolts.
      Torque: 18 lb.ft (25 Nm)
3. 1. Install the bump stop.
      Torque: 22 lb.ft (30 Nm)

1. Install the RH rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).

Tailgate in and out alignment - on hinge side

1. Open the tailgate.

1. Remove the fasteners and the tailgate hinge cover.

1. Mark the location of the tailgate hinge to aid in installation.

1. Loosen the bolts.
   Loosen:
   : 2 turn(s)

1. Close the tailgate.

1. Adjust the tailgate as required.

1. Open the tailgate.

1. Tighten the bolts.
   Torque: 30 lb.ft (40 Nm)

Tailgate in and out alignment - on latch side

1. 1. Remove the bump stop.
2. 1. Remove the bolts and the striker.
3. 1. Loosen the bolts.
      Loosen:
      : 2 turn(s)

1. Close the tailgate.

1. Adjust the tailgate as required.

1. Open the tailgate about 5 to 10 degrees.

1. Note down the movement in tailgate due to spare wheel removal. Noted movement due to tire weight should be accounted during final alignment.

1. 1. Tighten the bolts.
      Torque: 17 lb.ft (23 Nm)
2. 1. Install the striker and the bolts.
      Torque: 18 lb.ft (25 Nm)
3. 1. Install the bump stop.
      Torque: 22 lb.ft (30 Nm)

1. Close the tailgate.

All alignments

1. Install the spare wheel and the nuts.
   Torque: 41 lb.ft (55 Nm)

1. Inspect the body-to-tailgate door dimensions.

1. Install the positioned aside and removed components.

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[Stonetree]

Tailgate Alignment
Inspection

NOTE: Removal steps in this procedure may contain installation details.

1. Check tailgate-to-body dimensions.

Adjustment

All alignments

1. Remove the nuts and the spares wheel.
   Torque: 41 lb.ft (55 Nm)

1. Open the tailgate about 5 to 10 degrees.

1. Note down the movement in tailgate due to spare wheel removal. Noted movement due to tire weight should be accounted during final alignment.

Tailgate left and right, up and down alignment

1. Remove the RH rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
2. Open the tailgate.

1. 1. Remove the bump stop.
2. 1. Remove the bolts and the striker.
3. 1. Loosen the bolts.
      Loosen:
      : 2 turn(s)

1. Loosen the bolts.
   Loosen:
   : 2 turn(s)

1. Adjust the tailgate as required.

1. Tighten the bolts.
   Torque: 30 lb.ft (40 Nm)

1. Open the tailgate.

1. 1. Tighten the bolts.
      Torque: 17 lb.ft (23 Nm)
2. 1. Install the striker and the bolts.
      Torque: 18 lb.ft (25 Nm)
3. 1. Install the bump stop.
      Torque: 22 lb.ft (30 Nm)

1. Install the RH rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).

Tailgate in and out alignment - on hinge side

1. Open the tailgate.

1. Remove the fasteners and the tailgate hinge cover.

1. Mark the location of the tailgate hinge to aid in installation.

1. Loosen the bolts.
   Loosen:
   : 2 turn(s)

1. Close the tailgate.

1. Adjust the tailgate as required.

1. Open the tailgate.

1. Tighten the bolts.
   Torque: 30 lb.ft (40 Nm)

Tailgate in and out alignment - on latch side

1. 1. Remove the bump stop.
2. 1. Remove the bolts and the striker.
3. 1. Loosen the bolts.
      Loosen:
      : 2 turn(s)

1. Close the tailgate.

1. Adjust the tailgate as required.

1. Open the tailgate about 5 to 10 degrees.

1. Note down the movement in tailgate due to spare wheel removal. Noted movement due to tire weight should be accounted during final alignment.

1. 1. Tighten the bolts.
      Torque: 17 lb.ft (23 Nm)
2. 1. Install the striker and the bolts.
      Torque: 18 lb.ft (25 Nm)
3. 1. Install the bump stop.
      Torque: 22 lb.ft (30 Nm)

1. Close the tailgate.

All alignments

1. Install the spare wheel and the nuts.
   Torque: 41 lb.ft (55 Nm)

1. Inspect the body-to-tailgate door dimensions.

1. Install the positioned aside and removed components.

Thank you Flip! I guess there's nothing on the outside bolts I highlighted below?

 

[flip]

I've gone through just about every section in the WSM and can't find the value for the strap bolt torque. It's a M8 bolt but have no idea what class/grade. To be on the safe side I'd say 20 lb ft. If you have a torque wrench you could start at 20 and work your way up until it breaks loose and use that going back together. This could also have thread locker on it from the factory so YMMV.

 

[flip]

Yea, camera section.

Rear Parking Aid Camera
Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Release the clips and remove the liftgate trim panel.

1. Disconnect the electrical harness connectors.

1. Separate the grommet and position the wiring harness through the liftgate panel.

1. Remove the nuts and the spare wheel and tire assembly.
   Torque: 98 lb.ft (133 Nm)

1. Remove the bolts and the spare tire carrier.
   Torque: 18 lb.ft (25 Nm)

 

[Stonetree]

I've gone through just about every section in the WSM and can't find the value for the strap bolt torque. It's a M8 bolt but have no idea what class/grade. To be on the safe side I'd say 20 lb ft. If you have a torque wrench you could start at 20 and work your way up until it breaks loose and use that going back together. This could also have thread locker on it from the factory so YMMV.

Odd. I appreciate you looking. Good idea to get a general idea with a torque wrench. I'll make sure to put some blue Loctite on the threads to help. I think blue Loctite is supposed to require about 25% more torque to remove a bolt when used. So, I can do a rough calculation with that and the torque wrench. Thanks.

 

[DoYouBronco]

Awesome info guys! Surprised they left out the outer hinge torque specs but after installing and removing serval prototypes, the 18lbft recommended spec is staying tight and not damaging the finish on the plate.

 

[Stonetree]

Awesome info guys! Surprised they left out the outer hinge torque specs but after installing and removing serval prototypes, the 18lbft recommended spec is staying tight and not damaging the finish on the plate.

Works for me. Thank you.

 

[5280Bronco]

Ok, sorry. I'm still a bit foggy on some of the bolts.

Are the 8 bolts that hold the spare tire carrier to the tailgate 18-20lb ft? Or are they the 98 lbft?

If so, I gotta go torque those 8 bolts down more! Lol. I set them to 19.

 

[Stonetree]

Ok, sorry. I'm still a bit foggy on some of the bolts.

Are the 8 bolts that hold the spare tire carrier to the tailgate 18-20lb ft? Or are they the 98 lbft?

If so, I gotta go torque those 8 bolts down more! Lol. I set them to 19.

They're not 98. I think that's an error on the page. 18lb.ft is correct. 98 would damage the carrier. I think that 98 is referring to the 3 lug nuts for the spare tire. But even that's wrong. The spare tire lug nuts should be 41lb.ft.

 

[Stonetree]

I did the install today. Pretty easy. Great quality. So nice to have the creaking gone. My only complaint is the washers supplied for the tire carrier. They are too small to cover the original holes. I switched them out with 1” diameter washers. Much better.

 

[Pseudoko]

I did the install today. Pretty easy. Great quality. So nice to have the creaking gone. My only complaint is the washers supplied for the tire carrier. They are too small to cover the original holes. I switched them out with 1” diameter washers. Much better.

I've been eyeing this... so probably will be next on my list of things to get but need to save up a bit before spending more.

was the washer that you got 1" OD?

 

[Stonetree]

I've been eyeing this... so probably will be next on my list of things to get but need to save up a bit before spending more.

was the washer that you got 1" OD?

Yes. 1"OD

 

[5280Bronco]

They're not 98. I think that's an error on the page. 18lb.ft is correct. 98 would damage the carrier. I think that 98 is referring to the 3 lug nuts for the spare tire. But even that's wrong. The spare tire lug nuts should be 41lb.ft.

Thank you, I appreciate the info. I was just worried that the tire carrier was gonna fall off with spare on it if they were at 18 lbft. Nice to know that is correct. Lol.

Got it all installed, but it will have to wait till tomorrow to take it for a drive and see if it helped the creaking noises. My only issue with install was that the support was nicely curved left to right to match the tailgate curve, but I found that at the area it mounts to the body with the tire carrier, it was noticeably closer to the tailgate at the top than the bottom, so I had to bend/curve the mount by tightening down the bottom four bolts. It just made me cringe a bit, but I'm hoping it's fine. Did anyone else have that issue? Otherwise, I'm really happy with how it looks. I'll definitely want to get some black hardware for the hinge bolts when they are available.

 

[DoYouBronco]

I did the install today. Pretty easy. Great quality. So nice to have the creaking gone. My only complaint is the washers supplied for the tire carrier. They are too small to cover the original holes. I switched them out with 1” diameter washers. Much better.

Hey Ron!
Really appreciate the picture and feedback!
Can you get me a measurement and picture of the washers you received please, first I've heard of this...

 

[DoYouBronco]

Thank you, I appreciate the info. I was just worried that the tire carrier was gonna fall off with spare on it if they were at 18 lbft. Nice to know that is correct. Lol.

Got it all installed, but it will have to wait till tomorrow to take it for a drive and see if it helped the creaking noises. My only issue with install was that the support was nicely curved left to right to match the tailgate curve, but I found that at the area it mounts to the body with the tire carrier, it was noticeably closer to the tailgate at the top than the bottom, so I had to bend/curve the mount by tightening down the bottom four bolts. It just made me cringe a bit, but I'm hoping it's fine. Did anyone else have that issue? Otherwise, I'm really happy with how it looks. I'll definitely want to get some black hardware for the hinge bolts when they are available.

Yes its normal for the space between the tailgate and support bracket to slightly vary before you tighten down the tire carrier! Still working on testing different coatings and anodized black hardware.

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