Service Procedure
The following service procedure provides instructions for installing reinforcements to the rear liftgate and latch. All parts necessary to perform the installation are included in the kit. For additional information on trim removal, refer to the Body and Accessories section of the appropriate Service Manual or SI.Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Important
Read the complete service procedure before beginning the repair.
Before beginning, open the liftgate lock kit and review the contents.
^ (1) Outer Metal Strap
^ (1) Inner Metal "Z" Strap
^ (6) Rivets
^ (3) Replacement Latch Screws
^ (2) Bolts
^ (1) Striker Shim
1. Open the rear liftgate.
2. Release the four latches that secure the access trim panel to the inside of the liftgate, and remove the panel.
3. On vehicles equipped with an inside pull strap, remove the two screws that attach it to the liftgate.
4. On vehicles equipped with a "pocket" on the bottom edge of the interior trim panel, remove the two screws at the opening.
Notice
Failure to follow the next step in the exact sequence that it is written may result in damage to the interior trim panel. Read the entire step BEFORE doing anything.
Notice
Using tools other than those listed or using excessive force will damage the interior trim panel.
5. Release the retaining clips that attach the bottom section interior trim panel to the liftgate and partially lower the panel.
Important
The illustration shows the location of the twelve fasteners in the bottom section of the trim panel.
A. There are a total of twelve fasteners, six upper (1) and six lower (2), that must be released in order to "lower" the bottom section of the interior trim panel from the liftgate. The six upper retainers (1) must be released first.
B. Using the J 38778 (1), release the six upper retainers (2) from the liftgate. Do not attempt to release the six lower retainers until all of the upper retainers are released.
C. Once the six upper retainers (1) have been released, the interior trim panel (2) can be slightly pulled down in the middle to improve tool (3) access to the six lower retainers located down inside the panel.
D. Starting in the middle of the panel and working toward the outer edge, use the J 38778 (1) to release the three lower retainers (2) on the right side. Then repeat this step beginning in the middle and working toward the left side.
Notice
Do not allow the interior trim to "hang" for prolonged periods (lunch, breaks, overnight, etc.) after lowering it in the next step. Support the panel to the liftgate when necessary with strips of masking tape.
E. Carefully lower the bottom section of the interior trim panel (3) away from the liftgate (1) to access the small clear water deflector in the next step. It is not necessary to release the retainer 92) located on each side of the liftgate glass or the retainers along the top (above the glass) of the panel.
6. Remove the small clear plastic water deflector that covers the opening in the liftgate for latch access.
7. Remove the three TORX(R) head screws that attach the latch to the liftgate and discard the screws.
8. Remove the latch from the liftgate and disconnect the electrical connection.
9. Remove the nine screws that attach the liftgate lower molding to the exterior of the liftgate. The nine screws can be found along the inside bottom edge of the liftgate.
10. Carefully release the retainers that attach the upper edge of the liftgate lower molding to the tail lamp/license plate located directly above it. Remove the molding.
11. Once the liftgate lower molding has been removed, the section (1) of the liftgate where the reinforcement is to be installed can be seen.
Important
When the outer metal strap (3) is properly positioned in the next step, the curved corner on each end will align with the curved corners (2) on the liftgate. In addition, two of the three small holes (1) in each side of the strap will be upward.
12. Position the outer metal strap (3) to the outside of the liftgate as shown.
13. While holding the outer metal strap (1) in position, mark the location of the two holes (2) in the center of the strap on the liftgate with a pencil. Remove the outer metal strap.
14. Using a 5/16 inch drill bit, drill holes in the liftgate at the two locations marked in the previous step.
15. Position the outer metal strap to the liftgate and hold it in place with a couple of pieces of masking tape.
Important
The above illustration shows the inside of the liftgate with the latch removed (1) and with the inner metal "Z" strap (2) installed.
16. Install the inner metal "Z" strap (2) as shown inside the opening in the liftgate where the latch is located.
17. While holding the "Z" strap in position, install the two bolts through the holes of the outer metal strap, the liftgate, and into the weld nuts on the "Z" strap. Align the outer metal strap to the liftgate.
Tighten
Tighten the bolts to 10 Nm (89 lb in).
Important
Before making the holes in the next step, make sure that each section of the outer metal strap is flush to the liftgate. Starting at the center, apply pressure to the right side of the strap, working your way outwards towards the end. As you pass each hole, mark its location on the liftgate with the pencil. Repeat this procedure on the left side of the strap.
18. Using a pencil, mark the location of the remaining six holes in the outer metal strap.
19. Using a 3/16 inch drill bit, drill holes in the liftgate at the six locations marked in the previous step.
Important
A standard type rivet gun will be required for installing the rivets in the next step.
20. Beginning on the right side of the outer metal strap, and using the rivets supplied in the kit, attach the strap to the liftgate at the three drilled holes in the order listed below.
^ Inboard rivet
A. Center rivet
B. Outboard rivet
21. Repeat the riveting sequence on the left side of the outer metal strap.
22. Remove the masking tape.
23. Connect the electrical connectors to the latch and install the assembly back inside the opening in the liftgate. Install the three new bolts supplied in the kit.
Tighten
Tighten the bolts to 10 Nm (89 lb in).
24. Reposition the clear plastic water deflector over the opening.
25. Remove the striker (1) for the liftgate latch from the body.
Important
The purpose of installing the shim to the striker in the next step is to compensate for the thickness of the "Z" strap installed between the latch and the liftgate.
26. Install the shim included in the kit between the body and the striker.
27. Reinstall the bolts.
Tighten
Tighten the bolts to 25 Nm (18 lb-ft).
28. Position the liftgate lower molding to the exterior edge of the liftgate and engage the retainers along the upper edge.
29. Install the nine attaching screws along the inside bottom edge.
Tighten
Tighten the bolts to 2 Nm (18 lb in).
30. Position the interior trim panel to the liftgate and engage the retaining clips.
31. On vehicles equipped with an inside pull strap, position the strap to the interior trim panel and install the two screws.
Tighten
Tighten the bolts to 2 Nm (18 lb in).
32. On vehicles equipped with a "pocket" on the bottom edge of the interior trim panel, install the two screws at the opening.
Tighten
Tighten the bolts to 2 Nm (18 lb in).
33. Install the access trim panel to the inside of the liftgate, and secure the four latches.
34. Close the liftgate and verify latch operation.