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OK, tailgate strut job complete. total time including clean up 2.5 hrs. I didn't have a helper, so I used a very long stick to raise the hatch high enough to fully extend the struts. Any pressure on the struts will make it impossible to remove the pins at either end.
A couple of things I learned:
1. apply penetrating oil to the pins at the hinge end a few days
before starting. If your struts are really old, they will have
some corrosion on the end of the pin, making it very hard to
push the pin through the hinge. I had to tap the pin back into
the hinge with a long drift several times before it came out.
Getting the pins out took about an hour.
2. As the CD states, the struts(actually looks like a shock) is
removed in a forward direction, just make sure to detatch
the plastic clips holding the harness to the roof, one on the
left, two on the right.
3. to lower the headliner, start on one side, grip the headliner
and gently pull it backward and then down. Then detatch the
center mount, lastly, the remaining side. You will then see
two black rubber plugs holding the headliner up near the
quarter windows. gently pull those out. Then reach up behind
the headliner to the next steel speader and gently pull it down
a bit; it will stay down.
4. The CD doesn't mention this, but I found it easier to get the
plastic cover at the back of the headliner off by first removing
the left and right pillar covers. They come off by lifting up to
release the two plastic clips. The edges of all three plastic
panels tuck under the window rubber--pull carefully when
removing.
5. Before reassembly, wirebrush all four pins to remove any
burrs or debris. It will make your life much easier.
6. Lift the hatch high enough to slip the rear pins in first, then
put the clips on. Its tight ,but doable.
7. Lift the hatch higher than you might think to aign the
forward pins. This is where the helper comes in handy.
I didn't have one, so I used a long stick to raise the hatch
higher than necessary, then lowered it a little at a time
to get the end of the strut to align with the hole in the
body. The pins slip right in. Don't forget to re-bend the
securing tabs.
Not the easiest job, but with the bid from the dealer coming in at
nearly $600 parts and labor, I thought I'd give it a try.
Steve
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