Service Procedure A

This is the normal procedure to reinforce liftgate attachments that are not cracked and is only used when the spot welds on BOTH bracket attachments are free from any cracks or damage. The repair involves installation of a narrow reinforcement plate and is attached with four (4) rivets. This reinforcement plate will be referred to as the 4-rivet plate.

1. Open the liftgate and position a protective cover over the cargo area.

2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel.

3. Disconnect the lift cylinders from the upper lift cylinder brackets. keep the lift cylinders connected to the lower lift cylinder brackets.





4. Following the sheet metal contours, position the 4-rivet plate over the upper lift cylinder bracket. See Figure 1. If the lift cylinder bracket welds extend above the bracket surface, grind the welds flush with the bracket surface.

5. Using the 4-rivet plate as a guide, center punch the location for rivet # 1. See Figure 1. This rivet location cannot be on an existing weld.

NOTE:
IF VARIATIONS EXIST BETWEEN THE 4-RIVET PLATE AND THE LIFTGATE SURFACE, MODIFY THE PLATE TO CONFORM TO THE LIFTGATE INNER PANEL SURFACE WITH-OUT SCRATCHING OR BREAKING THE PAINT.

CAUTION:
Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel.

6. Drill a 5 mm (3/16-inch) hole for rivet # 1. Apply Super Seal Anticorrosion Compound (F3AZ-19515-SA) or equivalent to the hole to protect the bare metal from corrosion.

7. Position the 4-rivet plate and install rivet # 1. Make sure the plate fits tightly against the liftgate.

8. Using the 4-rivet plate as a guide, center punch the location for rivet # 2. See Figure 1.

9. Drill a 5 mm (3/16-inch) hole for rivet # 2. Apply Super Seal to the hole, then install rivet # 2.

10. Using the 4-rivet plate as a guide, center punch the locations for rivets # 3 and # 4.

11. Drill 5 mm (3/16-inch) holes for rivets # 3 and # 4. Apply Super Seal to the holes, then install rivets # 3 and # 4.





12. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 2. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally.

13. Drill a 5 mm (3/16-inch) hole at the center-punched location. Apply Super Seal to the hole, and install a rivet.

14. Repeat Steps 4 through 13 for the opposite side of the vehicle.

15. Connect the lift cylinders to the upper lift cylinder brackets.

16. Remove the jack stand.

17. Clean any excess Super Seal and metal shavings from the affected areas.

18. Verify liftgate operation.