Service Procedure
The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary.Notice:
It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables.
Support Cable Inspection
1. Open the rear tailgate and support it as necessary.
2. Release (unhook) the right side tailgate support cable from the pickup box.
Important:
In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance.
3. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands.
^ If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled, "Hinge Inspection"
^ If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled, "Hinge Inspection"
Hinge Inspection
1. Release (unhook) the RIGHT side tailgate support cable from the pickup box again.
2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate.
^ If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement," and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required.
^ If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step.
3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1), and a damaged or bent hinge (2).
^ If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required.
^ If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement".
Hinge Replacement
The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box.
1. Release (unhook) the left side tailgate support cable from the pickup box.
2. Remove the tailgate from the vehicle.
3. Remove the two bolts attaching the right side hinge to the tailgate.
Important:
The NEW hinge being installed must be primed and painted in the body color prior to installation.
4. Install a NEW hinge to the tailgate and install the two bolts.
Tighten
Tighten the bolts to 25 Nm (18 lb-ft).
5. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled, "Support Cable Replacement".
Support Cable Replacement
The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection.
Important:
If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall.
1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2).
^ If the toothed nut is present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step.
^ If the toothed nut is not present, proceed to Step 6.
2. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch.
3. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt.
4. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out.
5. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt.
6. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut.
7. Remove the bolt and support cable.
Notice:
Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will follow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer part number listed in this bulletin MUST BE used when installing the new support cables. It's dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall.
Important:
The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate.
Notice:
When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed.
8. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt.
9. Install the bolt, flat washer, and cable assembly into the latch and tailgate.
Tighten
Tighten the bolt to 25 Nm (18 lb-ft).
10. If the other bolt was loosened earlier, tighten.
Tighten
Tighten the bolt to 25 Nm (18 lb-ft).
11. Verify that the support cable end rotates freely on the bolt.
12. Attach the opposite end of the support cable to the pickup box.
13. Repeat the procedure on the other support cable.
Important:
Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to the overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall.
14. Remove the tailgate support, close, open, and re-close the tailgate. Verify that the support cables fold properly.