Not Built "Ford Tough" - Tailgate Trim Popping Out - How to Fix?

[Jim Lewis]

Today when I went to load some stuff into my truck bed, I noticed a plastic strip at the back inside top edge of my tailgate is popping out at one attachment point (see picture below). I tried pushing the bulge back in with my hand, even stomping on it with my foot. No luck. Does anyone know the proper way to reattach this trim? Is there a special tool required? Would the loose trim be a warranty issue that the dealer should fix?

As to what's causing the problem, my top theory is that if I put my Bak Mx4 tonneau cover down with the tailgate up, perhaps the bottom back edge of the tonneau cover is chopping the trim off the tailgate at the point of the problem. I've rolled a ~100 lb object on a dolly up a ramp onto the bed, but I don't think the dolly wheels transitioning in the slight gap between the top of the ramp and the inside top of the tailgate caused the strip to come loose. Another theory is that the intense Texas summer heat in some random asphalt parking lot caused the strip to differentially expand compared to the tailgate and pop out.

I have doubts whether all the fancy plastic tailgate "work surface" trim is built to handle all the loading/unloading of stuff I plan for my truck down the line. The miscreant bulge doesn't give me faith that the rest of the trim in the truck will be able to go the distance.

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[F150ROD]

Today when I went to load some stuff into my truck bed, I noticed a plastic strip at the back inside top edge of my tailgate is popping out at one attachment point (see picture below). I tried pushing the bulge back in with my hand, even stomping on it with my foot. No luck. Does anyone know the proper way to reattach this trim? Is there a special tool required? Would the loose trim be a warranty issue that the dealer should fix?

As to what's causing the problem, my top theory is that if I put my Bak Mx4 tonneau cover down with the tailgate up, perhaps the bottom back edge of the tonneau cover is chopping the trim off the tailgate at the point of the problem. I've rolled a ~100 lb object on a dolly up a ramp onto the bed, but I don't think the dolly wheels transitioning in the slight gap between the top of the ramp and the inside top of the tailgate caused the strip to come loose. Another theory is that the intense Texas summer heat in some random asphalt parking lot caused the strip to differentially expand compared to the tailgate and pop out.

I have doubts whether all the fancy plastic tailgate "work surface" trim is built to handle all the loading/unloading of stuff I plan for my truck down the line. The miscreant bulge doesn't give me faith that the rest of the trim in the truck will be able to go the distance.

The trim itself is nothing new and I’m sure some owners have already put it through the test with the ICE. I would ask them if it will be able to handle your demand.

Other than that, take it to the dealer but don’t tell them you’ve stomped on it or they’ll say you caused that trim piece to fail like that.

 

[Henry Ford]

I bet you can remove and reinstall that fastener pretty easily. The main plastic panel can be removed by taking out the exposed bolts. That will give you access to the bottom where you can push the failed fastener up from the bottom and hopefully not break it. It's possible it's already broken and you'll need a new fastener though.

What I described is worth avoiding a trip to the dealership to me. Your mileage may vary.

 

[Jim Lewis]

Other than that, take it to the dealer

I bet you can remove and reinstall that fastener pretty easily. The main plastic panel can be removed by taking out the exposed bolts. That will give you access to the bottom where you can push the failed fastener up from the bottom and hopefully not break it. It's possible it's already broken and you'll need a new fastener though.

What I described is worth avoiding a trip to the dealership to me.

Actually, if you have a tailgate step, the clips are readily accessible without unscrewing or pulling out anything. And, likely, inserting and/or removing the tailgate step from the tailgate was the cause of the broken clip and bulging trim strip that I depicted in my OP post.

In the first picture below, arrow #1 points to a broken part of the plastic clip. Arrow #2 points to a gouged part of the plastic inner tailgate covering that some workers at a recycling center today marred while trying to unload a 150- to 200-lb piece of old scientific equipment (again, so much for Ford Tough - the plastic tailgate cover is made to fall apart eventually with real-world use and workers struggling with unwieldy items ...).

The clip is a pointy male part within a female part. The first picture shows the broken clip sitting upside down on the lowered tailgate. In "insertable" form, the male part is withdrawn from the female part so the flanges around the female part are resting along the male part in the gap between the upper conical section and the two lower conical sections. This allows the male and female parts to be inserted into the hole in the cover strip over the hole in the tailgate metal. Then when the male part (imagine it rotated 180 degrees and right side up) is pushed further into the female part until it's flush with the tailgate deck, the two double conical sections push the flanges out and lock the clip in the tailgate. Apparently, just having one of these flanges break off on the female part is enough to make the tailgate clip (and the strip it secures) come loose.

So, if I can buy an unbroken clip in "insertable" form, it should be easy to secure the plastic strip on the tailgate. I presume to remove a clip, with the tailgate step lowered, all one probably has to do is gently push up on the end of the pointy male part to allow the flanges on the female part to collapse into the narrow space on the male part between the conical sections.

The second picture below shows the view of the top area of the lowered tailgate from below. The arrows point to the securing points for the plastic clips. There are flanges on the plastic strip that the clips secure that wrap around the sheet metal edge of the top of the tailgate and are perhaps designed to deflect the tailgate step downward so it doesn't clobber the plastic pins as you close the tailgate step. Guess it didn't work too well on my truck. Seems like a great Rube Goldberg design by FMC... ?

 

[sotek2345]

Actually, if you have a tailgate step, the clips are readily accessible without unscrewing or pulling out anything. And, likely, inserting and/or removing the tailgate step from the tailgate was the cause of the broken clip and bulging trim strip that I depicted in my OP post.

In the first picture below, arrow #1 points to a broken part of the plastic clip. Arrow #2 points to a gouged part of the plastic inner tailgate covering that some workers at a recycling center today marred while trying to unload a 150- to 200-lb piece of old scientific equipment (again, so much for Ford Tough - the plastic tailgate cover is made to fall apart eventually with real-world use and workers struggling with unwieldy items ...).

The clip is a pointy male part within a female part. The first picture shows the broken clip sitting upside down on the lowered tailgate. In "insertable" form, the male part is withdrawn from the female part so the flanges around the female part are resting along the male part in the gap between the upper conical section and the two lower conical sections. This allows the male and female parts to be inserted into the hole in the cover strip over the hole in the tailgate metal. Then when the male part (imagine it rotated 180 degrees and right side up) is pushed further into the female part until it's flush with the tailgate deck, the two double conical sections push the flanges out and lock the clip in the tailgate. Apparently, just having one of these flanges break off on the female part is enough to make the tailgate clip (and the strip it secures) come loose.

So, if I can buy an unbroken clip in "insertable" form, it should be easy to secure the plastic strip on the tailgate. I presume to remove a clip, with the tailgate step lowered, all one probably has to do is gently push up on the end of the pointy male part to allow the flanges on the female part to collapse into the narrow space on the male part between the conical sections.

The second picture below shows the view of the top area of the lowered tailgate from below. The arrows point to the securing points for the plastic clips. There are flanges on the plastic strip that the clips secure that wrap around the sheet metal edge of the top of the tailgate and are perhaps designed to deflect the tailgate step downward so it doesn't clobber the plastic pins as you close the tailgate step. Guess it didn't work too well on my truck. Seems like a great Rube Goldberg design by FMC... ?

Sidetracking this thread a bit since you know what you are talking about!

I recently transported a new fridge home and when getting it off the truck, I partially broke off the plastic trim/cover from the tailgate step. I was able to mostly put it back, but some of the molded on clips were broken on the bottom. Any idea how I can buy a replacement? Looking at parts sites, all I can see is a full step replacement.

 

[Jim Lewis]

Any idea how I can buy a replacement? Looking at parts sites, all I can see is a full step replacement.

For my broken strip pin part, I was musing whether it might be reproduced with a 3D printer if it's not available to buy. I recently bought my first 3D printer, but I've been too busy since getting the truck in May to learn how to use the printer. And the most durable plastic for a relatively low-end consumer 3D printer, ABS, gives off toxic fumes, so I'm wondering where I want to set the printer up (no room left in the garage with the truck!). We have an unused upstairs bathroom with an exhaust fan that vents to our unfinished attic, but the wife probably won't buy that.

I have a Garmin Oregon 400T handheld GPS unit. The plastic on/off switch broke off (a common failing for that device). Garmin no longer supports the device. But, IIRC, a 3D-printable part design is available for free on Thingiverse: Garmin Oregon On/ Off Button by DiggusNiggus - Thingiverse .

There don't seem to be too many Ford F-150 parts available to print on Thingiverse, though.

 

[sotek2345]

For my broken strip pin part, I was musing whether it might be reproduced with a 3D printer if it's not available to buy. I recently bought my first 3D printer, but I've been too busy since getting the truck in May to learn how to use the printer. And the most durable plastic for a relatively low-end consumer 3D printer, ABS, gives off toxic fumes, so I'm wondering where I want to set the printer up (no room left in the garage with the truck!). We have an unused upstairs bathroom with an exhaust fan that vents to our unfinished attic, but the wife probably won't buy that.

I have a Garmin Oregon 400T handheld GPS unit. The plastic on/off switch broke off (a common failing for that device). Garmin no longer supports the device. But, IIRC, a 3D-printable part design is available for free on Thingiverse: Garmin Oregon On/ Off Button by DiggusNiggus - Thingiverse .

There don't seem to be too many Ford F-150 parts available to print on Thingiverse, though.

I have been running a 3D printer for a few years (on my 2nd one) for personal use and to support the robotics team I coach.

Don't stress about the off gassing for ABS, it really is minimal. Open a window if you are really concerned. You will want an enclosure through to help maintain temperature. Without one, printing ABS is really challenging because it cools off too quick.

Feel free to send me a private message if you want any more tips. I am far from an expert, but do have some experience.

 

[Henry Ford]

Glad you figured it out, Jim. That fastener should be easily available at any Ford dealership.

If it were me I'd walk in with the part and look at parts diagrams with the parts department guys until we figured it out...but I live within five miles of three dealerships. I bet you could crowd source the part number on this thread in the alternative.

 

[Henry Ford]

Glad you figured it out, Jim. That fastener should be easily available at any Ford dealership.

If it were me I'd walk in with the part and look at parts diagrams with the parts department guys until we figured it out...but I live within five miles of three dealerships. I bet you could crowd source the part number on this thread in the alternative.

Well, it is me. One of the fasteners on my tailgate broke off. I've got a little time this afternoon so I'm going to see if Saline Ford has one in stock.

 

[MRButtler]

We broke a clip for the trim atop the step. Next time, we're using a rubber mat!

Also, Ford tough couldn't compete with the wife letting the 3 year old drive the zero-turn into a running board! Eeek!

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