GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Endgate

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REMOVAL & INSTALLATION



1994 Vehicles

See Figure 1

  1. Remove the torque rod:
    1. Access the torque rod bolts under the vehicle. With the gate closed, the bolts can be reached between the bumper filler pan and the frame. Unfasten the torque rod retaining bolts.
    2.  
    3. Remove the torque rod and brackets.
    4.  

  2.  
  3. Open the gate to the horizontal position.
  4.  
  5. If equipped, disconnect the rear window actuator release wire:
    1. Remove the trim panel.
    2.  
    3. Disconnect the wire from the actuator.
    4.  
    5. Disconnect the harness clip and the wire from the panel.
    6.  
    7. Remove the harness wire and grommet from the endgate, then disconnect the ground wire.
    8.  

  6.  
  7. Support the endgate in its lowered position using a table, a pair of sawhorses or an equivalent prop.
  8.  
  9. Disconnect the cable support bolts.
  10.  
  11. Remove the hinge pin "barrel'' clips by spreading the clip enough to move it above the recess in the pin; as the pin is removed, the clip will ride on the pin and then fall free of it.
  12.  
  13. Remove the hinge pins from the right and left hinges, then remove the endgate.
  14.  

To install:
  1. Support the endgate, with a table or suitable support, in a horizontal position.
  2.  
  3. Install the pins into the left and right hinges.
  4.  
  5. Connect the hinge pin clips to the hinge clips.
  6.  
  7. Install the cable support using the retaining bolts. Tighten the bolts to 25 inch lbs. (2.8 Nm).
  8.  
  9. If removed, connect the rear window actuator wire:
    1. Connect the harness wire and the grommet to the gate.
    2.  
    3. Connect the harness T-clip and the wire to the panel.
    4.  
    5. Connect the wire to the actuator.
    6.  
    7. Install the trim panel, then connect the ground wire.
    8.  

  10.  
  11. Install the torque rod:
    1. With the gate closed, place the torque rod and the brackets onto the vehicle. Tighten the bolts to 89 inch lbs. (10 Nm).
    2.  

  12.  
  13. Check for proper endgate operation.
  14.  



Click image to see an enlarged view

Fig. Fig. 1: Common endgate components-1994 vehicles

1995-96 Vehicles

See Figures 2, 3 and 4

  1. Remove the torque rod from the endgate.
    1. Access the torque rod bolts under the vehicle. With the gate closed, the bolts can be reached between the bumper filler pan and the frame. Disconnect the torque rod retaining bolts.
    2.  
    3. Remove the torque rod and the brackets.
    4.  

  2.  
  3. Remove the endgate door opening sill trim plate, using tool No. J-38778 or equivalent, to access the electrical wiring harness connector.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Endgate electrical wiring harness and washer hose connection-1995-9 vehicles

  1. Unplug the gate wiper and power latch release electrical wiring harness, then remove the washer hose and grommet.
  2.  
  3. Open the endgate to the horizontal position and safely support with a table, pair of sawhorses or equivalent prop.
  4.  
  5. Disconnect the cable support bolts.
  6.  
  7. On 1997-99 models, disconnect the lower end of the endgate strut from the ball stud on the gate by releasing the retaining clip.
  8.  
  9. Renove and discard the hinge pin retainers, then remove the hinge pins.
  10.  



Click image to see an enlarged view

Fig. Fig. 3: Endgate support cable-1995-9 vehicles



Click image to see an enlarged view

Fig. Fig. 4: Endgate hinge pins location-1995-9 vehicles

  1. Remove the endgate from the vehicle.
  2.  

To install:
  1. Safely support the gate in the open position, then install the hinge pins into the left and right hinges.
  2.  
  3. Connect the new hinge pin clips to the hinge pins.
  4.  
  5. Install the endgate cable support.
  6.  
  7. On 1997-99 models, attach the lower end of the strut to the endgate ball stud by pushing on the end of the strut.
  8.  
  9. Engage the gate wiper and power latch release electrical wiring harness, then connect the washer hose and the grommet.
  10.  
  11. Position the sill plate on the vehicle, then press it into place.
  12.  
  13. Install the torque rod:
    1. Install the torque rod to the tailgate, then with the gate in the closed position, place the torque rod and brackets onto the vehicle.
    2.  
    3. Insert the bolts which retain the torque rod, on 1995-96 models, tighten them to 89 inch lbs. (10 Nm).
    4.  

  14.  
  15. On 1997-99 models, tighten the bolts that attach the rod to the vehicle body to 89 inch lbs. (10 Nm) and the bolts that attach the rod to the insulator to the endgate to 18 ft. lbs. (25 Nm).
  16.  

ALIGNMENT



Align the tailgate so the gaps between all of the components are equal; it must be flush with the fenders. Center the tailgate in the opening between the fenders by adjusting the hinges and/or the striker bolts.

 
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