1992–1996 OBS Bronco Tailgate Removal & Installation Guide

This is best to be watched in our installation video provided above, but if you would prefer to have a step-by-step guide, we have provided one here as well.

• 7/16", 1/2", 9/16" sockets
• T50 Torx bit
• Ratchet + extensions
• Screwdrivers
• Drill + step bit
• Pry tool
• Grease + adhesive
• 12V power source + jumper wires
• Painter’s tape

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Safety & Prep (READ FIRST)

• Have at least 1–2 helpers (tailgate is heavy and awkward)
• Wear gloves → sharp edges everywhere
• Protect surfaces:
  • Towels / moving blankets on workbench
  • Painter’s tape on painted areas
• Expect:
  • Heavy components
  • Rusted or mismatched hardware
• Before painting a new tailgate:
  • Test-fit and pre-assemble EVERYTHING first
  • Drill all required holes BEFORE paint

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PART 1: Tailgate Removal

1. Lower the Rear Window

• Reconnect battery or use external power (12V)
• Apply power to window motor:
  • Positive → positive
  • Negative → negative
  • Reverse polarity if needed
• If stuck:
  • Manually assist or free glass

2. Open Tailgate Manually (if needed)

• Access latch rod inside
• Pull latch manually if handle is broken

3. Disconnect Wiring Harness

• Remove driver-side tail light (4 screws)
• Locate harness:
  • Tailgate → bedside
• Disconnect and move out of the way

4. Remove Torsion Rod Loop Bracket (CRITICAL STEP)

• Peel back weather stripping
• Use 7/16 socket
• Remove:
  • Top bolt first
  • Then slowly loosen bottom bolt
• Have helper hold tailgate pressure
• Carefully release tension (avoid injury)

5. Remove Tailgate Cables

• Remove bolts (size may vary: T50 / 1/2 / 9/16)
• Do BOTH sides

6. Remove Tailgate Hinges

• Remove two 9/16 bolts per side (jam area)
• With helpers holding tailgate:
  • Lift and remove tailgate from vehicle

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PART 2: Tailgate Disassembly

1. Remove Glass

• Raise glass halfway
• Remove 4 regulator nuts (7/16")
• Push regulator down, lift glass off
• Slide glass out carefully

2. Remove Seals & Trim

• Remove:
  • Glass weather strip
  • Inner/outer seals (Phillips screws)
• Be careful—likely brittle

3. Remove Run Channels

• Remove two 7/16 bolts per side
• Pull channels out
• Mark orientation (important!)

4. Remove Torsion Rod

• Remove retaining brackets (7/16 bolts)
• Pry rod out carefully
• Slide and rotate out of tailgate

5. Remove Regulator Components

• Remove arm rollers (tap off if stuck)
• Disconnect latch rods
• Remove latch assembly

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PART 3: Clean & Refurbish Parts

Clean & Restore:

• Glass
  • Vacuum debris
  • Clean with APC + non-abrasive pad
  • Optional: polish or #0000 steel wool
• Run Channels
  • Remove old weatherstrip
  • Clean, repaint (optional)
  • Apply clear coat
• Latch & Hinges
  • Soak in cleaner
  • Lubricate with spray grease
• Hardware
  • Clean rust
  • Repaint if desired

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PART 4: New Tailgate Assembly

1. Install Torsion Rod

• Insert 90° bend first (driver side)
• Slide across tailgate
• Seat into bracket
• Install retaining brackets + bolts

2. Install Bump Stops

• Push into rectangular openings until seated

3. Install Window Regulator

• Attach motor (8mm bolts)
• Ensure gear teeth mesh properly
• Install assembly into tailgate:
  • 5 mounting bolts total
• Tighten snug (don’t strip plastic threads)

4. Install Latch Assembly

• Position latch inside tailgate
• Install mounting bolts
• Install latch rods:
  • Clip securely into place
• Grease all pivot points

5. Install Tailgate Handle

• Insert handle through opening
• Install bolts (7/16)
• Attach handle rod to latch

6. Install Weatherstrips

• Apply adhesive to:
  • Channel AND weatherstrip
• Let tack, then install
• Allow ~24 hr cure

7. Install Run Channels

• Align with bolt holes
• Ensure correct orientation
• Leave slightly adjustable for tuning

8. Install Wiring Harness

• Route through tailgate
• Seat grommets
• Secure with clips
• Extend wiring if needed (for window motor)

9. Install Glass

• Grease regulator tracks
• Set glass onto rollers
• Install and tighten 4 nuts
• Test movement

10. Install Seals

• Corner seals (screw in carefully)
• Beltline seals (press clips into place)

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PART 5: Drilling New Tailgate (if applicable)

• Measure from original tailgate:
  • Spare tire carrier holes
  • Bumper pad holes
• Tape work area
• Drill:
  • Start small (1/8")
  • Enlarge with step bit
• Clean metal shavings

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PART 6: Tailgate Installation

1. Mount Tailgate

• Get help
• Align hinges
• Install 6 bolts
• Leave loose for adjustment

2. Install Torsion Rod Loop Bracket

HIGH TENSION – BE CAREFUL

• Helper holds tailgate nearly closed
• Install:
  • Top bolt first
  • Then bottom bolt
• Tighten fully

3. Install Support Cables

• Bolt both sides
• Tighten securely

4. Reconnect Wiring

• Route harness through bedside
• Seat grommet
• Connect all plugs

5. Adjust & Test

• Install strikers (T50)
• Adjust alignment:
  • Tailgate closing
  • Latch engagement
• Cycle window:
  • Ensure smooth operation

6. Final Assembly

• Install:
  • Access panel
  • Clips
  • Spare tire striker bracket
• Tighten all hardware 

Final Checks

• Tailgate opens/closes smoothly
• Glass moves freely (no binding)
• Latches engage evenly
• No wiring tension when window is down
• No paint damage

Pro Tips from the Video

• Always mock assemble before paint
• Take pictures during disassembly
• Label parts if needed
• Expect worn-out clips → replace them
• Don’t overtighten into sheet metal