Opening a sealed-top, broken handle and mech.rod tailgate at the LATCH?

I have a ridiculously inconvienient and clusterf*cked problem with my tailgate. Sorry it's a bit hard to explain...

I have a Truckboss snowmobile deck on the bed. It clamps down onto the top of the bed rails, is sealed all around and with legs into the bed floor (to support up to 1000+ lbs of deck and snowmobiles, it is a 7-hour installation to get it ON, there is NO WAY to get it off without opening the tailgate, so please don't ask if I can remove or lift it)... aaand it has my snowmobile on top of it. The ramp that I need to unload the snowmobile is under the deck, in a tray, behind the stuck tailgate.Yes, I know I can find another way to unload it but that is not the point, I need to get the tailgate open, period.

A few days ago on a trip to Mammoth in the parking lot in 19* weather, the plastic handle on the tailgate snapped off, locking me out of the bed. Tried cutting into the plastic with all the tools I had, to no avail. No professional services could or would help me get into it.

I went home, and drilled and cut out the plastic valence where the tailgate handle assembly is housed. Using pliers and a screwdriver I was able to rotate the handle/latch push/pull rod assembly and open the tailgate. I had to load up my sled and drive (snowmobile riding and filming commitment), and closed it to do that. Then the actual rod assembly fell off of the bed side end of the tailgate, into the tailgate. To be clear, the handle, center of the tailgate mechanism, is now 100% useless and my battle is entirely with the latches at the ends where the tailgate latches to the bed sides, with no push/pull rods to release them.

So now the latches at the end of the tailgate sides/bed side latches are closed, around the square "loops", D's, horseshoe latches whatever you want to call them, and I cannot disengage them from the inside of the tailgate anymore. I was able to get the tailgate slightly ajar (like halfway, 1 out of 2 clicks open), but not all the way. There is about a 1/4- a gap between the tailgate and bedsides and I can see the latch and fit tools into it. I spent some time trying to pry the jaws of the latches. One very un-helpful locksmith I took it to said there is no possible way to open those without being inside the bed or tailgate. Before I spend any more time trying, I want to know whether this is even a possibility.

The last resort would be to drill into and cut open the tailgate skin metal to gain access and reconnect the latch pull rods, destroying the tailgate.

Before getting that extreme, does anyone have any experience with this, think or know whether it is possible to release the latches from the gap between the bedsides and tailgate?

 

Oh, man. I can visualize exactly what you’re up against. I’m gonna go open my tailgate and see if I have any ideas.

 

Other than trying to "fish" with some sort of thin, J-hooked rod, I got nothing. Good luck, sounds like serious test of patience.

 

Wow, I’m sorry. Fresh out of ideas here.. so is the entire handle and mechanism off the tailgate, meaning there is an open hole there? I’m guessing you’ve tried fishing something in there like a coat hanger to reach the latches on the inside?

 

After looking at mine, I’d say that this is possible, but it might try your patience. You’ll want a 90degree pick. Something like:



Working through the gaps between the tailgate and the bedsides, you need get in above the loop attatched to the bedside and push each latch upward. It doesn’t look easy, but I do think it’s possible from the 1/2 latched position you’re in.

 

Wow, way more replies way faster than I expected, thanks, what a great community. If someone could try to post a pic of their latch on the tailgate side and as it closes around the rectangular "rings" on the bed sides of the tailgate opening, it might help me understand if this is possible and how.

 

Worst case scenario, it might be cheaper to cut the cathes/ D-ring things, than to cut into the tailgate?

 

Yes, that is exactly what I have been dicking around with for hours, although the pick I have been using is pretty small. I also tried various hex keys but most are too short, and the longer ones too big diameter. Maybe I can get a bigger pick or make a tool in my shop...

 

Hey you might be onto something here!!!

 

Here’s a poor picture in the dark of the passengers side. My key is pointing to where you need to push upward.


I’m sure I can take better pictures in the daylight tomorrow if you need.

 

Thanks Phil! You're awesome! I’ll hold on on cutting metal a bit longer. I am all out of beer... that usually helps

 

I took a few more pictures with a light. Not great, but better.




The piece you need to push upward is beside the little coil spring (its dirty and doesn’t look much like a spring) to the “outboard” end of the spring, right above the larger swinging jaw. Again, these are all the passenger’s side, the driver’s side is the same but mirrored. You’ll need to push upward there as well.

 

I drew an arrow right where you need to push upward with that pick.

 

One side open...!

 

Success with a new approach! I feel like an idiot. I should have removed ALL the handle area plastic sooner, but didn’t because I didn’t want to damage the backup camera or lock, or risk drilling to the metal. Eventually after hours of messing with a too-small pick, I decided to say f it and drilled and cut more plastic, ripped it all out, and could now fit my hand comfortably into the hole without many more cuts from plastic, place and shine a headlamp inside the tailgate and with a mirror, see the latch from inside the tailgate, and not actually re-connect the rod, but still pull the latch with it. It still took quite a few tries to get it, but it worked!

HUGE thanks to you @landphil ! I greatly appreciate your generous time and help.

Forensics:

The real culprits for this problem were:

- Cheap aftermarket plastic handle assembly that came with an aftermarket backup camera (which never worked after the first 3 times)

- 19 degree weather making cheap plastic brittle (shouldn't be a problem, but it was)

- Bedliner overspray on the push/pull rods. Apparently enough overspray can get between the cracks on the tailgate and onto the rods, adding texture and friction. It was like this when I bought it.

If you ever add an aftermarket backup camera, maybe try to use OEM handle assembly even though it costs 4x as much, not the supplied one and if you have or get bedliner, make sure your push/pull rods are still smooth afterward.

It just might save you a ski/snowboard/snowmobile trip, many hours of frustration, and some money.

 

The stock handle on my 07 seams kind of weak so I can only imagine what an aftermarket one would feel like. Before putting it back together I would clean everything up, remove any extra bedliner, and put some grease on it.

 

Broke my handle last year as well. Glad you got it open.

When I installed the new handle I soaked everything with a heavy silicone lubricant. Latches, rods, plastic, everything. It feels better than new now. I think the problem is there is a lot of resistance on a lot of surfaces and the plastic arms on the back of the handle just can't take it.

 

I read the story and then saw there was a good ending! Glad you got it open!

 

Thanks everyone. I will be replacing the arms entirely, and keeping them lubed.

 

Glad you got it open! I just broke my handle in 20 degree weather. Really am tempted to machine one out of aluminum.

 

How did u get it open? I have the same problem but it’s all the way closed

 

Bed is full and has a camper shell

 

So I got a 2019 tundra 1794 4x4 with the hard top cover. I am also locked out of bed. Here in Charlotte and we are having first freeze of season but Taking the family to celebrate chriat.as at beach tomorrow and trying to figure out how to open. I got a heat gun and was playing g with heating g up as seems like this happe s I cold weather but where would I heat. Any other suggestions appreciates.

 

Handle hasn't broke I can take it all the way up and feels like just not catching g or something. Help me get this open and functional.