Installing 4th gen tailgate on a 3rd gen truck

[chrisp2493]

I've seen pictures but crappy info on the web so I happened to find a good deal on a tailgate and jumped in. I found a black tailgate to match my truck but it was missing the handle, latches, spoiler trim and the cover plate. Talked the guy down and got it for $160, I couldn't believe it.
Also this thread will show you how to reuse all the parts off the old tailgates. If you have a tailgate with the hardware installed, the only thing that might need done is removing the torsion bar for the lift assist. I think you might be able to buy the bracket from the new trucks to use the bar, I haven't gotten that far though. So if you have the hardware, it should be as simple as dropping in the new gate and you're done with it. I wasn't so lucky.
Starting off my tailgate would not come off for anything. I got the passenger side lifted off but the left side wouldn't budge. I spent 2 hours banging and prying but it wouldn't move. Finally took it to a buddy's garage, hit it with the torch and it slid right off, go figure.
You'll need to remove the 4 star head bolts from the ends of the tailgate to take out the latches and the tailgate supports.
There is a large cover plate on the inside of the tailgate with 10 or so star bolts. Take those out to access the latch. This plate will fit right on the new tailgate if needed, everything lines up perfectly.
The latch and handle are held in with two 5/16 nuts. Unclip the connecting rods from the latch and everything should come out.




Sent from my iPhone using Tapatalk

 

[chrisp2493]

To start with the new gate, the latches and the supports should bolt right into the normal spots, plug and play. The handle and latch are where you have to start cutting and fabricating.
My handle didn't fit perfectly at first. The one tab on the right side wasn't lined up. All I had to do is mark where it was and drill out a small hole and it popped right in. It looked great, everything on the outside looks like the new ones
Since the new tailgates have the handle mounted on an angle on the wing instead of straight like the old gate, the latch doesn't quite fit.

I started out by cutting the mounting bracket right in the crotch where it bends in a 90
Next just cut off the bracket that goes across the top of the tailgate. It will be in the way of the latch
Now I just used some pliers the bend the metal down to where it was touching the back of the handle. Mark where the bolts touch and drill it out. Also on the right side you will have to notch out the side for some of the handle to clear
We got creative and got the grinder inside the tailgate


Sent from my iPhone using Tapatalk

 

[chrisp2493]

When the bracket is notched and bent it should look like this
As you can see the latch is now a few inches away from handle. Originally it is right on top of the handle. Now you need to make a small handle extension so activate the latch.
I drilled and tapped a hole in the end of the handle. I had a bolt with a flat head on it so I drilled that out and used it for the actuator. Then I lined it up with the latch lever, marked and drilled a hole for the actuator bolt to slide into.
There are better ways to do it then what I did, I just did it quick and with what I could find in the garage. The bolt was long enough that the tension of the latch made sure it would fall out. I put two nuts on the bolt that push the latch open. I left enough wiggle room so when the latch moves in a swinging motion, it doesn't bind up.
I mounted the latch by drilling two holes and bolting it to the mounting bracket. I didn't like this very much, it left some room for it to move if the bolts ever loosen up. I'm going to go back and just tack weld it to the bracket.
Hook up the connecting rods.
Screw on the cover plate.
The last thing to do is deal with the torsion bar on the bottom if it came with one. The one end of the bar has a slot that is supposed to go into a slotted mount on the truck. My truck didn't have that, so I'm searching for a 4th gen tailgate mounts and hopefully I'll be able to use that. If you need to remove it, loosen the holding bold on the passenger side, give it a yank and it will slide right out. Then make sure the tailgate bushings are in and it should be ready to hang on the truck.


Sent from my iPhone using Tapatalk

 

[chrisp2493]

I will get better pictures next week. I'm waiting for my ram head emblem and tailgate cap to be delivered. I'll debadge and clean up the crap on it, and get some good pics


Sent from my iPhone using Tapatalk

 

[Johnnymac2k6]

Do you think if you bought a 4th gen handle, all the fab would be necessary?

 

[chrisp2493]

Do you think if you bought a 4th gen handle, all the fab would be necessary?

I've never seen the inside of a 4th gen tailgate with the hardware installed to be positive, but I doubt it. Everything was stripped out of the tailgate when I bought it. The ONLY reason I did all that extra work was because I didn't want to spend $100 or more on the new handles. If you find a tailgate with all the parts to begin with, I think you can avoid all that work. So more or less, I proved the old hardware will work with some fabricating


Sent from my iPhone using Tapatalk

 

[Johnnymac2k6]

Yeah, dont take my questions as criticism at all. I admire the fab work for sure. And until an hour ago I had no idea this was even an option. I am completely re-skinning my 07 this summer and my tailgate is the last panel I need. Wondered if I found a complete tailgate that it'd bolt on. Or...buy the $150 replacement from key parts or Sherman, and a $30 replacement handle, and spare myself the cutting and all-thread. But regardless im impressed, and appreciate the thread. Awesome work!

 

[chrisp2493]

Yeah, dont take my questions as criticism at all. I admire the fab work for sure. And until an hour ago I had no idea this was even an option. I am completely re-skinning my 07 this summer and my tailgate is the last panel I need. Wondered if I found a complete tailgate that it'd bolt on. Or...buy the $150 replacement from key parts or Sherman, and a $30 replacement handle, and spare myself the cutting and all-thread. But regardless im impressed, and appreciate the thread. Awesome work!

Nope not feeling criticized lol I'm just super cheap. And trust me, the fab work looks like it's hillbilly rigged, nothing fancy. But I'm super excited that this worked, can't wait to get it finished all the way. I don't really know why this hasn't been done too much, maybe the the few panel lines being off are too much for some people. Are you doing any major body work that might look better matching up the wing?


Sent from my iPhone using Tapatalk

 

[Johnnymac2k6]

Nope not feeling criticized lol I'm just super cheap. And trust me, the fab work looks like it's hillbilly rigged, nothing fancy. But I'm super excited that this worked, can't wait to get it finished all the way. I don't really know why this hasn't been done too much, maybe the the few panel lines being off are too much for some people. Are you doing any major body work that might look better matching up the wing?


Sent from my iPhone using Tapatalk

I bought fiberwerx glass fenders and bedsides. And a glass ssk hood....and 4 new doors lol. I doubt id mess with the bedsides, but I could see filling the gap on the tailgate some if the spoiler piece doesn't fill it.

 

[akennedyusmc]

I like the custom fab work but really hope the innerds will work. I don't really have the time to tinker with that. Heading to pick and pull today


Sent from my iPhone using Tapatalk

 

[chrisp2493]

I like the custom fab work but really hope the innerds will work. I don't really have the time to tinker with that. Heading to pick and pull today


Sent from my iPhone using Tapatalk

Awesome! Good luck looking, glad I could plant the seed haha


Sent from my iPhone using Tapatalk

 

[Marciel]

Nice thread, that's awesome

Sent from my VS835 using Tapatalk

 

[chrisp2493]

My black ram head emblem and tailgate cap got in today, so I installed them and took the truck for a wash. Here are the completed pictures. If anyone is interested in this mod and need specific pictures, feel free to ask. Overall I'm super happy with the switch, it looks way better then before. I also took the old cover plate off, sanded it down and sprayed it with bedliner from a rattle can to match what was on the rest of the gate.
I only have two complaints so you can be aware or it. There is alittle bit more of a gap on both sides since the new tailgate is about 3/8" narrower. On one side the support strap sometimes sticks out because of the larger gap. Also since it's narrower, it will occasionally slide over a touch and not close. All it takes is a wiggle and it will work. Not a big deal but worth noting.







Sent from my iPhone using Tapatalk

 

[SilverStreak88]

Saw a red 3rd Gen today with a 4th gen tailgate, looked nice.

 

[akennedyusmc]

I like that. Super clean. Are you going to install back up camera in with the handle to tailgate? That's what I'm planning on doing if I find a silver tailgate.....


Sent from my iPhone using Tapatalk

 

[chrisp2493]

I like that. Super clean. Are you going to install back up camera in with the handle to tailgate? That's what I'm planning on doing if I find a silver tailgate.....


Sent from my iPhone using Tapatalk

No I don't think I'm going to. I never really felt the need to use the camera, just another expense for me


Sent from my iPhone using Tapatalk

 

[akennedyusmc]

Good point. It really is only for my wife when she drives. Plus just a real luxury for when I'm hookin up to a trailer lol


Sent from my iPhone using Tapatalk

 

[usaf2006]

I wonder if you'll fool any 4th gen owners out on the road

 

[chrisp2493]

I wonder if you'll fool any 4th gen owners out on the road

Actually people will think "that putz thinks he's fooling people that he has a nicer truck" haha


Sent from my iPhone using Tapatalk

 

[usaf2006]

Haha probably