Another Tailgate crack
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Elder User
Joined: Mar 2002
Posts: 549
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From: Huntsville, Alabama
Another Tailgate crack
My tailgate / Liftgate panel cracked today. I join all the other explorer owners who have experienced the same cosmetic flaw. 
I have included instructions from Ford on this for anyone else that may want to attempt this repair themselves. I will replace soon and I will show pictures of the process soon.
I have included instructions from Ford on this for anyone else that may want to attempt this repair themselves. I will replace soon and I will show pictures of the process soon.
Senior User
Joined: Mar 2004
Posts: 361
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From: Las vegas, Nevada.
Mine is not yet cracked however I notice that at least 75% of the Explorers I see driving on the streets are cracked, usually on the left side of the Ford emblem.
What causes this? Does it just crack for no reason or is it from the owner applying pressure to this area when closing the rear hatch?
What causes this? Does it just crack for no reason or is it from the owner applying pressure to this area when closing the rear hatch?
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Elder User
Joined: Mar 2002
Posts: 549
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From: Huntsville, Alabama
I am guessing fatigue life has been met through expansion and contraction of the plastic panel. I can assure you that we have not slammed or pressed the panel harshly. Like you I saw many others cracked and I was extra careful. Notice that after 2005 there was a re-design?
Senior User
Joined: Mar 2004
Posts: 361
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From: Las vegas, Nevada.
Yes, I have seen that, No more plastic piece, just metal to the window.
These Explorers seem to have quite a few flaws. I'm having second thoughts about owning one. This back panel is the least of my worries.
These Explorers seem to have quite a few flaws. I'm having second thoughts about owning one. This back panel is the least of my worries.
Mountain Pass
Joined: Jul 2003
Posts: 225
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From: Southwestern Ontario
The panel on my Aviator cracked, was replaced and then cracked the following winter.
It happened when I closed the glass section of the tailgate and pushed on the panel section while closing in cold weather.
Now I push on the wiper motor, or the glass. No cracks yet.
When closing the whole tailgate, I push on the steel section near the licence plate.
I totally avoid pushing on the plastic panel.
If it ever cracks again I'm going to fill it with JBweld, sand and paint it.
It happened when I closed the glass section of the tailgate and pushed on the panel section while closing in cold weather.
Now I push on the wiper motor, or the glass. No cracks yet.
When closing the whole tailgate, I push on the steel section near the licence plate.
I totally avoid pushing on the plastic panel.
If it ever cracks again I'm going to fill it with JBweld, sand and paint it.
New User
Joined: Oct 2014
Posts: 3
Likes: 0
From: PA
Bumping up an old thread.
The last poster said he was going to try JB Weld if his cracks again. Does anyone know if that would work? Anyone have a DIY solution other than replacing the plastic piece, which could then crack again? Any OEM or after-market replacements that use a more durable type of plastic?
We have a 2005 Explorer, and after years of watching others' tailgates crack, ours cracked in July 2014. Wife is now making it an issue and agitating for a fix, and I'd like to avoid buying her a new vehicle if at all possible!
The last poster said he was going to try JB Weld if his cracks again. Does anyone know if that would work? Anyone have a DIY solution other than replacing the plastic piece, which could then crack again? Any OEM or after-market replacements that use a more durable type of plastic?
We have a 2005 Explorer, and after years of watching others' tailgates crack, ours cracked in July 2014. Wife is now making it an issue and agitating for a fix, and I'd like to avoid buying her a new vehicle if at all possible!
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Post Fiend
Joined: Apr 2002
Posts: 19,311
Likes: 97
From: Waterloo, Iowa
JB-Weld is pretty good stuff actually. There might be a better product for your application, maybe. It can be sanded, drilled, machined etc. and handles high temps and low temps, oils and fuel, and is nonconductive. When I was in the .mil we had a pretty good selection of similar epoxies, even "5 Minute" cots purchases in the little packets. The strongest as I recall though, was popularly called "the pink sh_t" because that was the color.
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Post Fiend
Joined: Apr 2002
Posts: 19,311
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From: Waterloo, Iowa
Can't remember anymore, but the popular names. It was bubble gum pink. There was also other materials that had slang names, called "Elephant snot" and "Peanut butter". I think the latter referred to a type of lubriplate.
Senior User
Joined: Oct 2014
Posts: 153
Likes: 0
I thought the initial problem behind the cracking of the panel was the adhesive that was used to secure the plastic panel to the gate...it didn't allow for proper flexing of the panel, thus causing the cracking. The fix was a different adhesive which allowed for the flex.
If that's the case, then I'd think JB Weld would just fill the crack in the mean time but still wouldn't solve the overall issue...
If that's the case, then I'd think JB Weld would just fill the crack in the mean time but still wouldn't solve the overall issue...
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