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Dodge Ram P/N D80006 Installation Instructions

November 26th, 2009 · No Comments

1. Remove tailgate by disconnecting the tether cable and lifting the tailgate out at approximately a 45º angle. (Reference the truck’s Owner’s manual)
2. Carefully remove the OEM tailgate pivot cups from the tailgate taking note of which side they belong on.
3. Remove tether bolt. A special wrench may be required.
4. Remove latch pin bolt. A special wrench may be required.
5. Figures 1 through 5 show the three styles of TireGates
6. Install the supplied pivot cups and the right and left OEM pivot cups in the left and right side uprights. See Figure 6.
7. Slide the torque tube onto the left and right upright mount. See Figure 1.
8. With the left and right uprights pushed in on the torque tube, install onto the pivot cups and install the torque tube bolts and washer, 4 places (M10X70MM bolt , washer and lock nut) to keep the uprights from turning. DO NOT tighten lock nuts yet.
9. Due to truck manufacturing tolerances, it may be necessary to loosen the bolts attaching the truck’s tail gate pivot pin(s) to properly locate the TireGate’s left and right uprights.
10. Start the top uprights bolts (M10×100m), washer and support washer (the support washer goes in between the truck and the up rights) and the lower upright bolts (M10×100mm). DO NOT tighten the bolts.
NOTE: To mount the TireGate in the inboard direction, install the latch pin cable bracket on the left side lower bolt. For the outboard direction, install on the right side location. See Figure 6.
11. Pull both the left and right uprights in while tightening the 4 torque tube bolts. M10X70MM torque to 30-35 ft/lbs.
12. Tighten the 2 left and right upright bolts. M10 torque to 35-38 ft/lbs.
13. If necessary, tighten the bolts securing the truck’s tail gate pivot pin(s) to factory specs.
14. Install bushings on the TireGate. The slotted bushing will be installed on the latch pin side and positioned so the slot is across the truck. The pivot bushing will be installed on the hinge side of the TireGate. See Figure 1.
15. Lift the gate and install both latch pins to hold gate in position to assist in assembly.
16. To install black plastic thrust washers, hold them on the top and the bottom of the gate as you slide the gate into the upper and lower clevises. Insert M10X100M hex bolts (Note: Grease the shaft of the bolt before installation. Do not grease the trust washers) Tighten just enough to take the slack out of the bolts and then torque to 18-22 ft/lbs. DO NOT over tighten the lock nuts.

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