putting a new tailgate on 98 Dodge caravan

[paulmpianist]

Hi.. I'm about to put a new tailgate on a 98 Dodge Caravan. I got hit in the back and I bought a new back door at the junk yard.
It looks pretty easy, but I thought I would touch base here and see if anybody might have done it before because there are a couple of potentailly tricky parts...

Does that wire bundle have a block somewhere that you can plug, or am I going to be splicing them one by one? (I don't have power locks. I have windshield wiper, back door inside light, license plate light, heat wires in the glass.)
The other tricky part..changing the lock. Any insight on how that works would be really appreciated.

I think that's all.. the bolts and star screws look pretty straightforward.
Thanks a lot... this is a great car. I got it used with 48k miles a couple years ago and I only have 75k now. It was a government car.
thanks again,
paul

[Cntrysthbst]

the lock cylinder has a u-clip on it, and a clip holding the metal rod, should be easy, have to take off the interior panel on the back of the tailgate to get to it.

if you open the tailgate, the very rear upper panel has 2 screws holding it in place, think its metal, taking that off and alittle of the right pillar, you will see the main plug. a red tab needs pulled to unplug and can pull it through the body. the rubber seal the harness wire goes through needs pulled out to so the harness plug can fit through. and dont forget about the washer fluid hose. there should be a coupling to unplug in the same area. the shocks pop off once you remove the clips that attach to the tailgate side. its not a one man band taking off and installing the tailgate. two people holding it up while another removes and installs the bolts are best, unless one person is strong enough to hold the whole thing up himself...if no help, maybe make a platform with a couple latters with the tailgate open to rest on it. meaning 2 latters on each side..couple 8' 2 by 4's to each latter and plywood on top. wouldnt hurt to screw together and bunge cord 2 by 4's to latter to for extra stability.

if your old tailgate has options the new tailgate doesnt you might want to change out the tailgate wire harness. options like rear defrost, flood lights, inter wipers, alarm, power locks (which you said you didnt have). if you do any splicing do make sure you solder back together, chrysler/dodge are very sensitive when it comes to voltage.

i remember i had to adjust the tailgate once and it was a pain to get it lined up, keeping the bolts tight but not torqued so i could use a hammer and screw driver to adjust seemed to work for me. the latch that the tailgate closes on is adjustable too, you need to take the bottom panel off and i think there are 3 star screws.

another thing...this is for a 4th generation minivan, 2001-07. from what ive seen at junk yards both 3rd and 4th wiring/bolt locations look almost the same just different body styles.

if you have more questions, or need more help, will be happy to help...good luck!

[paulmpianist]

Thanks A LOT..!! You've been a great help! thanks very much,. I'm going to print it out and go over it a lot before I get some guys to help me. That is some great detail you went into... even tighten the bolts but don't torque them down until you bang it around with a hamme to line it up.. thanks again,
sincerley
paul

[Cntrysthbst]

you run into any problems let me know, also was thinking...when you are adjusting the door keep the shocks off till you get it aligned with the body frame, after that and bolts are torqued you can put shocks on...remember, the door is heavy, when opening and closing it for adjustments be careful. if i think of anything else will let you know.

[paulmpianist]

Hi.. thanks for the help and tips about putting this door in. I know its been a few months since the door got installed, but I just wanted to ask about a followup issue. the door lights, brake lights windshield wiper, defroster wires in the back door all work. BUT... there are some side-effects. Now my dashboard instrument lights are dim. If I roll the dimmer switch until the interior lights come on .. it also makes the instrument lights bright again.
(One other side effect, but I don't care about this.. when the doors are open the ceiling/interior lights don't come on automatically anymore, but I really would just like to see the instruments better..)
Mostly I have to guess what speed I'm going. I can see it sort of.. but I might be going 55 or 65 and not know very clearly.

Ok thanks for any input. I'm not going to mess with it too much.. I don't want to "fix" it and have something go really wrong.
Bye the way .. I drive a 98 Caravan, but its a Voyager door. I only have 78, 000 miles on it. I really like this car. Worst thing... worse than the lights.. I bought a console and so now I have 6 cup holders that drop cups.

[AndrewG]

It could be a coincidental failure of your headlight switch. I had that problem and that was the culprit.