1991-1994 Explorer & Navajo Tailgate: The Falling Liftgate Recall and Rust Guide

Safety Recall: Risk of Falling Liftgate

This issue is documented in NHTSA Campaign ID Number 99V310000 (Ford Campaign Number 99S34) for 1993-1994 Ford Explorers and Mazda Navajos. Similar issues were reported for 1991-1992 models as well. The fix involves installing a reinforcement bracket kit. Before purchasing a used tailgate or inspecting your own, check if this reinforcement has been installed. If your liftgate struts are attached to a secondary, thicker bracket in addition to the original body mount, the repair has likely been done. If not, assume the vehicle is affected and exercise extreme caution when the liftgate glass is open.

Common Symptoms of Tailgate Failure

Owners of the first-generation Ford Explorer and its twin, the Mazda Navajo, often experience a handful of common problems with the rear tailgate assembly. Recognizing these symptoms can help you diagnose the issue correctly.

1. Rust Damage

By far the most common issue for these 30-year-old vehicles is rust. Moisture gets trapped inside the tailgate shell, causing it to rust from the inside out. Key areas to check are:

• Bottom Seam: The lower edge of the tailgate, both on the inside and outside, is the most frequent spot for rust. You may see bubbling paint or feel softness in the metal.
• Around the Window: The seal for the flip-up glass can trap water, leading to rust forming around the window opening.
• Behind Trim and Emblems: Moisture can collect behind plastic trim pieces and the Ford/Mazda emblem, causing hidden rust.

2. Flip-Up Window Problems

The upper glass portion of the tailgate has several components that can fail:

• Weak or Failed Gas Struts: If the glass window won't stay open on its own, the gas-charged support struts have lost their pressure and need to be replaced. This is a simple and common repair.
• Broken Latch or Handle: The handle for the flip-up glass is made of plastic that becomes brittle with age and can break, making it impossible to open the window.
• Loose or Wobbly Hinges: The hinges at the top of the glass can wear out, causing the window to feel loose or misaligned when closed. This can lead to water leaks and wind noise.

3. Main Tailgate Latch and Handle Failure

The lower tailgate can also have problems with its opening mechanism. The exterior handle can break, or the internal latch rods and clips can fail, preventing the gate from opening when you pull the handle. Sometimes you may hear a click, but the latches on the sides do not release.

4. Electrical Issues

The wiring that runs from the vehicle body to the tailgate must flex every time the gate is opened and closed. Over decades, these wires can break. This can cause the rear window defroster, rear wiper motor, or license plate lights to stop working. A visual inspection of the wiring harness boot can often reveal damage.

Buying a Used Tailgate for Your Explorer or Navajo

Since new OEM tailgates are no longer available and complete aftermarket assemblies are not produced, buying a quality used OEM part is the only practical option. Careful inspection is critical to avoid buying a part that is in worse condition than your current one. Here’s what to check:

Inspection Checklist:

• Rust is the #1 Enemy: Bring a small magnet and a flashlight. Thoroughly check the bottom lip of the tailgate, inside and out. Press firmly on this area to check for soft spots hidden under the paint. Check around the window frame as well. Minor surface rust can be treated, but avoid any tailgate with holes or deep, flaky rust.
• Verify Your Options: This is the most important compatibility check. These tailgates came in several configurations. You must match your vehicle's original options:
  • Rear Wiper: Does your truck have a rear wiper? The mounting holes are different between wiper and non-wiper models. You cannot easily add a wiper to a non-wiper tailgate.
  • Glass Tint: Does your vehicle have factory privacy tint (dark) or clear glass? Make sure the replacement matches to avoid a mismatched look.
• Inspect the Glass: Check the glass for scratches. If it has a defroster, look closely at the grid lines to ensure they aren't scraped or broken.
• Check the Wiring Harness: Look at the wiring harness where it exits the tailgate. Ensure the connector is intact and no wires have been cut. A damaged harness can be difficult to repair.
• Test the Latches: If possible, operate the exterior handle and the flip-up glass handle. They should move smoothly and feel connected to the internal mechanisms.

Cost Comparison

Replacing a damaged tailgate involves several potential costs. Here is a general breakdown:

Replacement Overview

• Difficulty: 3/5 (Moderate)
• Estimated Time: 1.5 - 2.5 hours
• DIY Feasible: Yes, but it is a two-person job due to the weight and size of the tailgate.

Replacing the tailgate assembly is mechanically straightforward. The basic steps involve removing the interior trim panel, disconnecting the electrical connector, supporting the tailgate's weight, unbolting the main support straps or cables, unbolting the gas struts for the window, and finally unbolting the main hinges from the body. Installation is the reverse of removal. Having a helper is essential to prevent injury and avoid scratching the vehicle's paint.

Technical Specifications

OEM Part Numbers

These part numbers are for reference and may represent different configurations (with/without wiper, etc.). Always verify fitment with the seller based on your vehicle's specific options.

• Ford: F17Z-7840010-CA, F17Z7840010DA, F1TZ-7842006-C, F2TZ-7840010-A, DB07991YP, DB08243YP
• Mazda: ZZL2-62-020, ZZL2-63-931, ZZL3-62-020, ZZL4-63-931

Frequently Asked Questions (FAQ)