S10 Repair Project update - tailgate bracket

[firestorm31]

Recap:Tailgate latch bracket -
two bolts apparently worked loose, prolly as a result of the tailgate cable which corroded & broke. From the looks of it, I'd have to remove the tailgate housing to access the area of the bolt hole (for a lack of a better word)This job looks pretty easy. I unscrewed 2 screws with philips screwdriver and pulled or rather wrestled the tailgate out of its socket. I looked inside to see if the 2 nuts were inside.. no such luck. it looks like the nuts worked itself loose and popped out of the truck thru an open clearance below.

I did find out a bit about the nut, apparently it uses whats called a nut-washer and they cost like 7.00 from the GM service parts dept. I put an order for 2 of 'em. I suppose I could have just gotten a seperate washer & nut cheaper. :D

however, I did make the mistake of buying new tailgate cables from the GM service dept, they were $25 each, yikes. I found out later that I could have gotten it for half that price.

[firestorm31]

I got one of the cables removed by drilling, but I think I might have damaged the tailgate when I went lil bit too deep. :eek: eek!

anyone know how to fix that?

I think I messed up on the correct way to drill. I think had drill bit usage reversed. I think mis-read the instructions. It calls to use 1/8"bit to start it off and then to use 3/8" bit to get the head off. Instructions then say to remove the bolts from the brackets and use the drill to get the bolt out.

however, I've hit a little snag.

I can't remove the 2 bolts that hold the latch bracket from the tailgate in order to remove the bolt stem.

my drill with the screwdriver Torx bit couldn't move it. :Gnasher_1!!!!!!

are the bolts held by nut inside the gate?

note to self .. please wear gloves when using drill. I had mild blisters on my thumb-hand.

[firestorm31]

I got one of the cables removed by drilling, but I think I might have damaged the tailgate when I went lil bit too deep. :eek: eek!

anyone know how to fix that?

I think I messed up on the correct way to drill. I think had drill bit usage reversed. I think mis-read the instructions. It calls to use 1/8"bit to start it off and then to use 3/8" bit to get the head off. Instructions then say to remove the bolts from the brackets and use the drill to get the bolt out.

however, I've hit a little snag.

I can't remove the 2 bolts that hold the latch bracket from the tailgate in order to remove the bolt stem.

my drill with the screwdriver Torx bit couldn't move it. :Gnasher_1!!!!!!

are the bolts held by nut inside the gate?

note to self .. please wear gloves when using drill. I had mild blisters on my thumb-hand.

I found the solution in removing the torx bolts that were screwed in pretty tight - use an impact wrench.

I had to get a couple of pieces for the impact wrench, a T40 3/8" socket & 1/2" F to 3/8" socket. I used my vehicles impact wrench used for removing wheel bolts. They did the job, unfortunately, the wrench's cigarette lighter line wasn't long enough to reach the top bolt. I had to get an cigarette extension cord from Best Buy. Now all the 4 bolts have been removed, now the brackets can be moved somewhat away from the tailgate.

Ok, I worked on the 2nd cable and got it right this time.

I made sure to put something behind the rivet, in this case a piece of the broken cable. I drilled it out with 1/8" drill bit to start with and drilled with a bit 1 size under 3/8" drill bit. I forgot what size it was.

both cables & rivets are now out. The T40 bolts are now screwed back in.

the only thing left is to fix the hole. it is not round, somewhat oval. I guess I need to get a step bit for that. I understand that its good for enlarging an existing hole nice and round. A visit to Home Depot or Lowes is in order!

btw, what length bolt do I need to bolt in the new cables? the new cables did not come with bolts or screws.

[87wildside]

No help on the bolt sizes but the step bit is what you need. If you have Harbor freight around they have nice ones. Been using the same ones for 2 years on 3/16 steel...lol

[firestorm31]

No help on the bolt sizes but the step bit is what you need. If you have Harbor freight around they have nice ones. Been using the same ones for 2 years on 3/16 steel...lol

thanx for mentioning Harbor Frieght.

I thought it wa a mail order outfit until I noticed that it had a page mentioning store location and found that there was indeed one in my area.

Sniff, Home Depot & Lowes are somewhat over priced on the step drill. If their website's any indication, I hope HF store is the same.

[firestorm31]

thanx for mentioning Harbor Frieght.

I thought it wa a mail order outfit until I noticed that it had a page mentioning store location and found that there was indeed one in my area.

Sniff, Home Depot & Lowes are somewhat over priced on the step drill. If their website's any indication, I hope HF store is the same.


I went there the other day bought some stuff. some of the items are way cheaper than Home Depot or Lowes. like one step bit costs only 7.00 or to get a set is like around 12.00. Not bad prices.

Its a shame that a lot of this stuff is made in china, of course excepting Taiwan.

[firestorm31]

What to do with the bolts for the tailgate....

It looks like I need at least 1/4" length bolt.

I went to Advance Auto & Pepboys to see if any of their tailgate cables had bolts packaged. I did find one for the S10. I wish I had bought those. it had the parts need. What it had was something called a rivet mount and a C/E ring. The rivet mount appeared to be about 1/4" length x 1/4" diameter. the stores appear not carry the rivet mounts. Incidentally, they are made by Dorman Products under the Motormite & Help! label.

I looked at the 3/8" bolts which seems to be recommended by a bunch of people. They didn't have any at 1/4" length in stock. Smallest they carry is 1/2".

Looks like I may have to cut the 1/2" length bolts down to size, get a lock nut, 2 washers and a spacer.

[firestorm31]

more on the bolts.

will this do the trick?

zinc
http://www.boltdepot.com/product.aspx?cc=69&cs=247&cm=7&cd=1821
http://www.boltdepot.com/product.aspx?cc=69&cs=251&cm=7&cd=1826

stainless steel
http://www.boltdepot.com/product.aspx?cc=69&cs=247&cm=6&cd=1821
http://www.boltdepot.com/product.aspx?cc=69&cs=252&cm=6&cd=1824

shoulder bolt - stainless steel - this maybe it, not sure about the size tho.....
http://www.boltdepot.com/dimension.aspx?cc=67&cs=244&cm=6