I climbed into my 91 bronco this evening on my way home from work. When I closed the drivers door, the tailgate glass exploded! Nothing was touching it, the window was up. weather stripping is in fair condition. Has anyone else heard of this happening?

 

Yup. Misalignment between top and tailgate is typically the culprit especially if the top is not secured tightly. This can also happen if the tailgate interlock switch that keeps the window from moving if the gate isn't shut fully has been bypassed. With this scenario, the window can be raised and essentially jammed into the weatherstripping/window-run in the top and may even close/seal well enough to keep the elements out. However the misalignment puts sheer pressure on the glass between the top and the gate. The sudden air pressure change or vibration of the slamming driver's door takes it out. There are a couple other possibilities but this is the one I've seen take out the glass second most often.

The number one glass killer is a rusted torsion bar mount in the floor of the gate that gives way and lets the bar slam into the window. However this can only happen with the glass at least halfway down or more.

 

Stupid torsion bar...

 

I'm going to guess it probably was a malfunctioning passenger side latch. the bigger problem I'm finding now is getting a tinted and heated window to replace the broken one. I've looked at every online site I could find so far, nothing. Called several glass repair shops and only response they can give me is "have to try the salvage yards". The rear defroster was a factory option on my '91. I would like to use it! Ford changed something in late '87 that made the earlier windows not compatable. Installing a new latch and a used rear glass for now. Any ideas where to find the right window, new? Will have to visit a few salvage yards when I get time. If I can find the right glass, I might buy as many as they have!

 

Safelite has replaced several for me and other folks around here in the past. If the glass is suddenly unavailable, its news to me. Both of mine have the rear defrost grid.

 

Tnx Grey! I'd forgotten about them. They closed their shop in Norfolk a few years back. They are still in business in Columbus, about 45 miles further from me. They have one ordered for me, cash and carry price of abt $140. Yf was going that direction for doc appt so no special trip required Now if my camber bushings would show up I'll have plenty of wrenching to do this weekend!

 

So when this torsion bar mount snapps, which mine just did and took my window out, whats the fix? a new tailgate or is there another option???

 

Yeah, cancel the gym membership as the tailgate will give you all the workout you'll need.

My tailgate doesn't have the torsion bar, but I know that and have gotten used to the weight. Never felt it with the bar so I don't know what I'm missing, but its not that bad I think.

 

You could fabricate a new stop for the bar if you had the expertise to do so. Otherwise the original stop is a part of a gusset on the floor of the tailgate. Once it rusts away, its gone.

 

I drilled two holes in the lip of the access panel hole. Used a small "U" bolt to secure the top of the drivers end of the torsion bar again to the tail gate, not against the glass. If you need the brackets that hold the bar to the bottom of the tail gate I have two brand new ones.

 

I might have to try the u bolt trick, but at the same id like a new tailgate. I like new stuff. My glass will be here wednesday so I have a little time to decide, even though its supposed to snow... I need my bronco ready!

 

by the way my glass was all the way up/closed and the torsion bar still managed to shatter it. My torsion bar is half way up the access panel right now..

 

By the weight of my t-gate, I'd say my bar is missing/broke. Need new gate anyway so just going to suffer the extra weight. (don't let the wife open it!)

 

My bar did not break. When it got heavy closing I found the bar against the glass when the peice of metal holding it rusted away. Use a camera to see what is happening.

 

You got lucky there b4. The stop typically lets go as you try to close the gate causing the bar to slam into the glass. Sounds like yours released slowly enough or at a time when the gate was open and didn't take the glass with it.

V8, if you decide to replace the entire tailgate, I recommend having the INSIDE of it rhino-lined or some similar product to keep corrosion at bay. (Just keep the drain holes clear). We are all aware that the rust begins in the seam where the outer skin and inner panel of the gate are joined and the trough created by the lower seam is actually higher than the drain holes so water will remain trapped along to bottom edge of the gate about 1/2 to 3/4" from the bottom edge (where they show signs of paint bubbling first). The gussets, including the one that holds the torsion bar in place, are down in that area as well. Anything to keep the moisture and crud out of direct contact with the metal surface is going to help. there are photos in my gallery of the inside of the one I had Rhino-lined. That gate lasted several years on GS92 until the fire claimed her life... however, I still have that tailgate and in spite of the fire damage and having sat outside for years since, it is NOT rusting in the typical locations. Just some food for thought.