Mikz86TA
04-09-08, 10:14 PM
Every since I bought the truck new the tailgate hanlde has never been cosmetically adjusted right. Compared to other makes and models, the S10 handles were low-sitting in the opening. I attempted to readjust it once with minimal results. So today I had some spare time and decided to embark on the project. I bought a Pop-N-Lock tailgate lock assembly. It was not going to install easily or correctly with the handle in the OEM position. So that was another reason for the motivation to fix this.:D
This is very easy if you have about 1 hour and some tools.
Picture of where I started. This was after an adjustment with the stock openings.
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle1.jpg
Tools needed :
T-30 Torx driver
Small Rasp File bit or
Round Grinding Stone or
Rat-tail FileStep 1 :
Start by removing the plastic tailgate handle trim shroud. Bend it downward in the top center slightly with your fingers or a tool that wont scratch up the paint. After the 2 catch tabs clear, rotate the top outward. Then pull it up to free the bottom 2 catch tabs and set aside.
Step2 :
Next use the T-30 Torx to remove the 3 bolts holding the latch assembly on the inside of the tailgate. Try to loosen them and repositioning the tailgate handle upwards. There is 'some' adjustment and play from the factory. You may be lucky and get it right without any modifications. Mine had little but not nearly enough. If you cant get it high enough to readjust as I show in the pictures, then go on to the next step. Dont worry, latch assembly wont fall into the tailgate. There is a metal support under it and the still-attached rods will keep it near the opening.
Step 3 :
With the Torx screws you removed, use them to mark the area you are going to remove. The goal is to make the round holes the Torx were in, into a oblong or capsule-sheped hole. You are wanting the hole to become a slot that will allow the assembly to be moved/adjusted upwards. The thickness of the threaded end of the Torx is where I would start. I had to go a little farther. Be sure NOT to make the hole bigger from side-to-side unless you also have a 'centering' issue.
**In the pictue, you can see one hole is still round and as it was stock. The other two holes are starting to be made into oblong holes going upwards.
**One hole stock os already a little oblong.
Picture of one orig hole and the other 2 starting to be modified:
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle2.jpg
Step 4 :
Use the grinder stone or rat-tail file or other tool to grind or file the holes into the oblong shape. I used a modified rat-tail file on the end of a power drill. Its faster that way. I would advise a near the same size round grinding tool for you to more precisely accomplish the task. Use common sense!
**For the top hole I had the handle in the lowest out-of-the-way position. But for the bottom holes, I had to hold the handle assembly up out of the way for my fileing tool to have movement.
Step 5:
Periodically test fit the handle and handle trim back in place. In the last picture you will see the difference and what gap level you are trying to acheive. My top hole came very close to the curve in the inner tailgate skin. You will still want a small amount of gap as pictured, so in the future the handle trim can be easily removed and installed.
Picture of how much I actually had to oblong the holes to acheive satisfaction:
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle4.jpg
Step 6 :
After you are satisfied, reinstall the handle assembly. Hold it all tha way up while you tighten it and keep it straight. Dont forget to put some paint on the bare metal where you ground off to prevent rusting!
Now, it looks sooo much better and matches the side doorhandles perfectly as far as fit and finish! The metal handle does have a natural slight arch to it. As you see in the pic, it makes the gap line not perfectly straight. But from a normal distance its hard to see that.
Finished project up close :
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle3.jpg
I installed the Pop-n-Lock for future security. I plan on adding some LED taillamps and then a tonneau later. Most tonneaus lip over the back and secure the tailgate shut, but I may end up with a Checkmate cover which does not. So a tailgate lock is essential if I have valubles in there.
The lock bracket mounts in with the 2 lower handle bolts. It sort of lays over the top and sandwiches the orig handle mount inside the tailgate. In order to do this, Pop-n-Lock provides a couple security one-way bolts that are a smaller diameter than the orig lower handle bolts. They go throught the original handle bracket threads (they dont thread to the OEM handle) and screw into the threads on the P-n-L bracket. Its not difficult but requires a little finagleing to get both the handle and lock assembly adjusted perfectly. But once its on it looks good. I went to Lowes and picked up some stainless steel bolts. Just because they wont rust out.
Its not bulletproof. I could definately still break in if I wanted too. But it does work well and would ward off 90% of an attempted theft.
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle6.jpg
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle5.jpg
This is very easy if you have about 1 hour and some tools.
Picture of where I started. This was after an adjustment with the stock openings.
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle1.jpg
Tools needed :
T-30 Torx driver
Small Rasp File bit or
Round Grinding Stone or
Rat-tail FileStep 1 :
Start by removing the plastic tailgate handle trim shroud. Bend it downward in the top center slightly with your fingers or a tool that wont scratch up the paint. After the 2 catch tabs clear, rotate the top outward. Then pull it up to free the bottom 2 catch tabs and set aside.
Step2 :
Next use the T-30 Torx to remove the 3 bolts holding the latch assembly on the inside of the tailgate. Try to loosen them and repositioning the tailgate handle upwards. There is 'some' adjustment and play from the factory. You may be lucky and get it right without any modifications. Mine had little but not nearly enough. If you cant get it high enough to readjust as I show in the pictures, then go on to the next step. Dont worry, latch assembly wont fall into the tailgate. There is a metal support under it and the still-attached rods will keep it near the opening.
Step 3 :
With the Torx screws you removed, use them to mark the area you are going to remove. The goal is to make the round holes the Torx were in, into a oblong or capsule-sheped hole. You are wanting the hole to become a slot that will allow the assembly to be moved/adjusted upwards. The thickness of the threaded end of the Torx is where I would start. I had to go a little farther. Be sure NOT to make the hole bigger from side-to-side unless you also have a 'centering' issue.
**In the pictue, you can see one hole is still round and as it was stock. The other two holes are starting to be made into oblong holes going upwards.
**One hole stock os already a little oblong.
Picture of one orig hole and the other 2 starting to be modified:
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle2.jpg
Step 4 :
Use the grinder stone or rat-tail file or other tool to grind or file the holes into the oblong shape. I used a modified rat-tail file on the end of a power drill. Its faster that way. I would advise a near the same size round grinding tool for you to more precisely accomplish the task. Use common sense!
**For the top hole I had the handle in the lowest out-of-the-way position. But for the bottom holes, I had to hold the handle assembly up out of the way for my fileing tool to have movement.
Step 5:
Periodically test fit the handle and handle trim back in place. In the last picture you will see the difference and what gap level you are trying to acheive. My top hole came very close to the curve in the inner tailgate skin. You will still want a small amount of gap as pictured, so in the future the handle trim can be easily removed and installed.
Picture of how much I actually had to oblong the holes to acheive satisfaction:
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle4.jpg
Step 6 :
After you are satisfied, reinstall the handle assembly. Hold it all tha way up while you tighten it and keep it straight. Dont forget to put some paint on the bare metal where you ground off to prevent rusting!
Now, it looks sooo much better and matches the side doorhandles perfectly as far as fit and finish! The metal handle does have a natural slight arch to it. As you see in the pic, it makes the gap line not perfectly straight. But from a normal distance its hard to see that.
Finished project up close :
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle3.jpg
I installed the Pop-n-Lock for future security. I plan on adding some LED taillamps and then a tonneau later. Most tonneaus lip over the back and secure the tailgate shut, but I may end up with a Checkmate cover which does not. So a tailgate lock is essential if I have valubles in there.
The lock bracket mounts in with the 2 lower handle bolts. It sort of lays over the top and sandwiches the orig handle mount inside the tailgate. In order to do this, Pop-n-Lock provides a couple security one-way bolts that are a smaller diameter than the orig lower handle bolts. They go throught the original handle bracket threads (they dont thread to the OEM handle) and screw into the threads on the P-n-L bracket. Its not difficult but requires a little finagleing to get both the handle and lock assembly adjusted perfectly. But once its on it looks good. I went to Lowes and picked up some stainless steel bolts. Just because they wont rust out.
Its not bulletproof. I could definately still break in if I wanted too. But it does work well and would ward off 90% of an attempted theft.
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle6.jpg
http://i157.photobucket.com/albums/t43/Mikz86TA/Truck/Mods%20and%20Work/S10-TailgateHandle5.jpg