Chevrolet LIGHT DUTY TRUCK (SERIES 10-35) Service Manual page 151

2D-22 BODY
Coach models (06) and utility models (16) use endgates
of similar, yet distinct design. Separate procedures follow
for service on each of these endgates.
ENDGATE ASSEMBLY - (06) MODELS ONLY
Replacement
1. Lower endgate, and removed hinge access covers.
See figure 2D-57.
2. Remove endgate-to-hinge bolts.
3. Remove L.H. torque rod bracket, shown in figure
2D-58.
4. If equipped with
disconnect wiring harness.
5. Lift endgate to almost closed position and remove
support cables.
6 . Remove endgate with torque rod.
7. To install, reverse removal procedure.
HINGES
Replacement
If necessary to remove hinges, remove endgate as
outlined previously, and proceed as follows:
1. Remove bolts from each of the hinge assemblies on
the underside of the body. See figure 2D-57.
2. Remove hinge assemblies. If the hinge pins are to
be removed, note the position of bushings so they may be
reinstalled in the same position.
3. Reverse procedure to install.
ENDGATE DISASSEMBLY
1 . Remove access cover shown in figure 2D-59, to gain
access to interior components.
2. Detach remote control rods from lock assembly by
removing clips.
3. Remove bolts securing lock assembly, and remove
lock assembly.
4. Remove handle assembly bolts and remove inside
LIG H T T R U C K SER V IC E MANUAL
ENDGATES (06 AND 16)
electric powered window,
handle.
5. Remove R.H. torque rod bracket screws, figure 2D-
58, then remove torque rod from endgate.
6 . Remove screws connecting cam assemblies to sash
assembly, figure 2D-60, then remove cam assemblies.
7. Remove glass from endgate.
. Unclip and remove inner and outer seal assemblies.
8
9. Remove screws connecting window regulator
assembly to endgate, figure 2D-60, and remove regulator.
CAUTION: Step 10 must be performed if
the window is removed or disengaged
from the regulator lift arms. The lift arms
are under tension from the counter­
balance spring, and can cause injury if the
motor is removed without locking the
sector gears in position.
10. For endgates with electric window, secure the
window regulator lift arms before removing the electric
motor, when the window glass has been removed or
disengaged from the lift arms.
a. Drill a 1/8 (3.1mm) inch hole through the sector
gear and back plate, as shown in figure 2D-60. Install a sheet
metal tapping screw into the hole to lock the sector gears
in position.
b. Remove the regulator motor attaching screws and
remove the motor assembly.
11. From inside the endgate, remove the nuts fastening
the outside handle to endgate and remove the outside
handle. See figure 2D-61.
If equipped with power tailgate window, detach wiring
harness from motor.
12. Remove side bolts connecting left and right glass
channels to endgate and remove channels.
13. Removed side latch bolts and remove side latches