Tailgate Installation / Adjustment

Tailgate Installation / Adjustment

Special Tools Required
- Tailgate Height Step Gauge 07AAG-SJCA100
- Tailgate Left Hinge Alignment Fixture 07AAG-SJCA200

NOTE: This procedure is based on these conditions:
- Tailgate panel removed.
- The rear bumper removed.
- Tailgate removed.
- The left tailgate upper striker and the right tailgate upper striker removed from vehicle.
- The right tailgate lower striker is installed onto the vehicle with the bolts snug enough to allow the striker to slide up or down.
- The left tailgate upper latch and the right tailgate upper latch are installed onto the tailgate with the bolts loosely installed.
- The left tailgate lower hinge and the right tailgate lower hinge are installed onto the tailgate with the hardware hand tight, allowing some movement of the latch/hinges.
- All shims are installed in their original locations (if any).




1. Place the left tailgate hinge alignment fixture (07AAG-SJCA200) over the hinge (A). Insert the pins (B) through the holes in the alignment fixture and into the holes (C) in the hinge. With the alignment fixture firmly and squarely against the side and the lower edge of the tailgate, apply pressure to the side of the alignment fixture at the side of the tailgate (D) first, and then simultaneously apply pressure to the side of the alignment fixture at the bottom of the tailgate (E). Using a T50 Torx bit and ratchet, tighten the bolts hand tight.
2. Remove the alignment fixture, and torque the three bolts to 40 N.m (4.1 kgf.m, 30 lbf.ft).




3. Position the lower edge of the right tailgate lower hinge (A) 19 mm (0.75 in.) below the bottom edge of the tailgate (B). Measure from the hinge at the seam (C). Using a T50 Torx bit and ratchet, torque the four bolts. After tightening the bolts, recheck the measurement.
4. Using a screwdriver, latch the left tailgate upper latch.




5. Apply masking tape (A) to the left side of the tailgate (B) and the inside of the tailgate opening on the body (C).




6. Carefully position and hold the tailgate in the tailgate opening, and latch the right tailgate lower latch (A). Continue to hold up the left side of the tailgate, and install the original shims (B) (if any) between the left tailgate lower hinge (C) and the body (D), then loosely install the lower two bolts in the hinge.




7. Lower the tailgate, and loosely install the remaining three bolts into the left tailgate lower hinge.
8. Raise the tailgate, and hold it in place.




9. Apply a strip of masking tape on the right upper side of the tailgate (A).Apply another strip of tape next to it on the body (B).




10. Using the body lines (A) as a guide, hold the right side of the tailgate at the correct height. Make a horizontal line across both strips of tape (B), then make another mark (C) 20 mm (0.79 in.) above the first mark on the body side.
11. Carefully use the tailgate lower handle to release the right tailgate lower latch. Do not lower the tailgate.

NOTE: When you release the right tailgate lower latch, the tailgate is only supported by the left tailgate lower hinge.

12. Insert the tailgate height step gauge (07AAG-SJCA100) on top of the right side bumper foam (A), supporting the right side of the tailgate under the hinge. Keep the right lower hinge as close to the striker as possible without touching. Position the step gauge so the mark (B) on the tailgate (made in step 11) aligns with the higher mark (C) on the body side.






NOTE:
- Make sure the left upper corner of the tailgate rests forward against the body.
- Note the step number on the gauge where the latch rests.




13. Insert a pry bar between the right tailgate lower striker and the right tailgate lower hinge. Have an assistant apply pressure to move the tailgate to the left.




14. With the assistant still applying pressure, raise the left side of the tailgate to align the body line of the body (A) and tailgate (B), and torque the four left tailgate lower hinge bolts.
15. Carefully lift and hold the tailgate in the upward position and remove the step gauge, allowing the tailgate to sag supported by the left tailgate lower hinge. Do not latch the right tailgate lower latch.
16. Check the height of the right side of the tailgate. The alignment mark (A) made on the tailgate side should line up with the lower alignment mark (B) made on the body side. If the tailgate is not aligned, loosen the two left lower hinge bolts on the body and repeat steps 12 through 15, step gauge, as needed.






NOTE: When repeating steps 12 through 15, the mark on the tailgate may not align with the mark on the body. The higher mark is only used as a starting point.

17. Still holding the tailgate in the upward position, latch the right tailgate lower latch. Continue to hold the tailgate upward.




18. Move the right tailgate lower striker (A) to align the body lines (B), then torque the three lower striker bolts.




19. Lower the tail gate, and torque the one remaining left tailgate lower hinge bolts and the one right tailgate lower striker bolts.




20. Raise the tailgate. Inspect the gap between the left upper tailgate and the body.




21. Open the tailgate about 70 mm (2.75 in.), and then let go of the tailgate. The tailgate should begin to fall open on its own, if does not, repeat steps 12 through 15 and use the next step lower on the height gauge.
22. Pull the tailgate upper handle to release the left tailgate upper latch, and then lower the tailgate.
23. Install the left body-side striker/hinge with the bolts hand tight, allowing some movement of the striker/hinge.




24. Raise and close the tailgate firmly. The left body-side striker/hinge and the tailgate latch/hinge align themselves. Push in on the upper left of the tailgate and hold it, and then use a T50 Torx bit and extension, tighten the center bolt (A) hand tight on the left tailgate upper striker (B).




25. Torque the three left tailgate upper latch bolts.




26. Lower the tailgate. Remove the from the left upper tailgate latch, and apply liquid thread lock to the nut. Reinstall the nut and tighten it to the specified torque.




27. Torque the left tailgate upper striker bolts, starting with the center bolt first.
28. Install and torque the tailgate support cable.




29. Close the tailgate. Check the flushness of the tailgate to the body at the top of the tailgate. If the left side is out of specification, install or remove shims between the left striker/hinge and the body as needed (go to step 24). If the right side is out specification, install or remove shims between the right tailgate lower hinge and the body as needed (go to step 18).




30. Lower the tailgate, and install the right tailgate upper striker with the two screws hand tight. Make sure the striker is positioned horizontally.




31. With the right upper tailgate latch bolts hand tight, position the latch in the upward position.




32. Close the tailgate, making sure both latches are latched. Make sure the right striker (A) is in the lower range of adjustment within the tailgate latch (B). Grab the top, center of the tailgate, and push and pull it inward and outward a few times to center the right upper tailgate latch.




33. Lower the tailgate. Make sure the right tailgate upper latch alignment marks (A) are at equal positions, and torque the right tailgate upper latch bolts and the right tailgate upper striker screws.
34. Loosely install the tailgate trim panel, and check the dual-mode tailgate operation.
35. Install the tailgate trim panel.
36. Check the dual-mode tailgate operation.

NOTE: When closing the tailgate from the lowered position, apply a slow steady pressure to the top, center of the tailgate. Be sure that both the left and right latches close simultaneously. If they latch independently, and the tailgate is not fully latched, the tailgate may not open in swing mode.

37. Check tailgate switch operation.
38. Reinstall the taillights.
39. Reinstall the rear bumper.