Know How Notes – Broken Tailgate Handle Repair

Saturday morning, you pull up to the local lumber yard with your list of supplies needed to finish the deck, replace those busted sprinkler heads, or whatever you have been putting off for months. Your shopping bag is full of all sorts of home-repair supplies. And then, you reach for the handle at your truck’s tailgate and there is nothing. Is that it? What? The handle’s reason for being in this world is to open the tailgate. It is then given a few more tugs. The dang thing is ruined, it’s no longer functional as a tailgate handle. But don’t worry, we are about to teach you broken tailgate handle repair.

Table of Contents

The tailgate handle on this 2002 Chevy 2500 HD is not working, so we need to pop the cover off and take a look. — This 2002 Chevy 2500HD’s tailgate handle has stopped working. Let’s take the cover off and inspect it.

Finding The Root Of The Problem

This can happen on any truck, but it doesn’t have to. The problem is not in the tailgate handles, but rather the latches. There are two latches on each side of the tailgate. These latches can become dirty and rusty over time. The lubrication that has dried and the latch becomes stuck can cause damage to the handle’s cast iron arms. These arms can break if you put too much stress on them.

The plastic arms were intact, it is common for these to break. Unfortunately, this truck has a broken handle mechanism. — The plastic arms were still intact. It is not uncommon for these to fail. This truck’s handle mechanism is broken.

Fixing The Problem

Luckily NAPA has the fix for both issues. NAPA Solution Parts stocks replacement handles for many of the most popular trucks. This problem was encountered on a 2002 Chevrolet truck. It was a recently purchased truck and the tailgate handle broke when it was bought. We went to NAPA to get a replacement handle cover and a NAPA Solutions handle. The original plastic cover had broken when it was taken off to open the tailgate.

The plastic clips just pop off of the rods, then the rods pulls out of the handle arm. — The plastic clips simply pop off the rods and then the rods come out of their handle arm.

Repairing the broken tailgate handle is very simple. There are only three bolts to remove the rods, and then a few plastic clips that hold in place the rods that control the latches. We removed the bolts from the handle and took the clips out. The handle can now be replaced, but what about latches? If you don’t take care of the latches now, the new handle will just break again down the road.

There are three bolts inside the bed that hold the handle in place. They are metric 13 mm on this truck. You can see the left-side lever is broken, there should be a tab to push on the arm. It is missing. — The handle is held in place by three bolts within the bed. These bolts are 13 mm in length on this truck. The left-side lever on the truck is broken. There should be a tab that allows you to push the arm. It is missing.

The latches are held in place by two bolts on each side. You can only remove one bolt at a time. The tailgate cable must also be removed.

The latches are the main issue, as they get corroded and dirty. Two bolts hold them in. Only do one side at a time. — They get dirty and corroded, which is the main problem. They are held in place by two bolts. One side only.

We took the latch out and used Slip Plate Black Ice graphite perforating oil to lubricate it. The penetrating oils helps to pull graphite into the inner workings. When the oil dries, the latch will have graphite protection.

The latch is dirty and dry, so we knocked the dirty and crud off of it first. — We removed all dirt and crud from the latch before it dried.

We used Slip Plate Black Ice lubricant to provide long lasting lubrication. You can use a plain wet lube, but the graphite in Black Ice will last much longer. — Slip Plate Black Ice was used as a lubricant. It provides long-lasting lubrication. A plain wet lubricant will work, but the graphite found in Slip Plate Black Ice will last longer.

The tailgate was closed, and the latches were put back in place. The rod must not pass behind the handle recess. Otherwise, the handle will need to be removed.

When the latches are reinstalled, you have to make sure the rod goes above the recess for the handle, otherwise you will have to pull it out and reinstall it. — After the latches are removed, ensure the rod is above the recess. Otherwise, you’ll have to take it out and reinstall.

The original hardware was used to install the handle. Don’t forget to snap the latch rods into the plastic clips.

We picked up a new NAPA Solutions handle and trim cover for the truck for a perfect fit. — For a perfect fit, we bought a NAPA Solutions handle cover and trim cover.

The handle installs just like it came out. — It installs exactly as it came out.

Then the three bolts reinstalled and tightened down. — Finally, the bolts should be reinstalled.

Don't forget to attach the rods to the handle and clip them in. — Don’t forget to attach the rods to the handle and clip them in.

Installing the plastic cover is the last step. You can reuse the cover if it’s not damaged. Our cover had all four tabs broken.

We popped the new cover into the hole. All done. — The new cover was inserted into the hole. All done.

It took some effort to get the tailgate open before we repaired it. After the repair, the tailgate latch was as smooth and easy to open. It takes about 15 minutes to repair a broken tailgate handle.

Check out all the body & accessory products available on NAPA Online or trust one of our 17,000 NAPA AutoCare locations for routine maintenance and repairs. Chat with a local expert at NAPA AUTO PARTS to learn more about fixing a broken tailgate handle.

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Know How Notes – Broken Tailgate Handle Repair

Finding The Root Of The Problem

Fixing The Problem

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