Solved: How to Slightly Modify the Tongue Jack to Allow Tailgate Clearance

georgianwinds

How to Modify the Tongue Jack to Allow Tailgate Clearance

After purchasing a new tow vehicle, I found that I needed a few extra inches of clearance to allow my truck tailgate to drop without hitting the jack handle on my 2019 T@B. I wanted easy access to my covered truck bed while travelling, my setup does not allow for a folding side mounted jack and I preferred not using an extra long hitch ball mount. So the easy solution was to simply remove the jack handle and replace the handle with a 1/2 inch diameter hex head bolt. The tailgate now clears. Using a 3/4 inch nut driver in my drill I could really quickly lower or raise the tongue jack. Using the manual crank for the scissor jacks (also 3/4") could always be a backup to the drill.  Problem solved. A $1.50 bolt and about one hour of work.

Steps

Remove the cover plate. Knock out the pin holding the handle in place using a punch and a hammer. Save the pin. Pull out the jack handle. Cut the one and a half inches of thread off of the new bolt leaving 3 1/2 inches of unthreaded bolt. File any burrs off of cut end. Lining up the old handle with the bolt, mark the position of the new hole on the bolt and then drill a 5/32 inch hole in the bolt. Grease the bolt and gears (if needed) , insert the bolt and replace the pin. Reattach the cover plate and test using a drill fitted with a 3/4 inch nut drive. 

Good to go and clears the tailgate. Pictures follow.

Materials Required

(1) 5” long hex head Zinc plated bolt (1/2” diameter)

Tools

Flat head screwdriver

Hammer

Punch

Hack saw

File

Drill (drill press preferred)

5/32” drill bit

Grease

rcarlson1957

Great idea. I use a jack e up and remove my jack when traveling. 

Dalehelman

That looks very familiar.

Verna

Yes, @Dalehelman, your good ole 3/4” bolt is being used by others!  

Dalehelman

@Verna 1/2” to be exact. 2015
Did you get yours installed?

Verna

@Dalehelman, hopefully this week. It’s a long story…..

ColinsTab400

Thoughts on reversing the hanidle to the inside?   Just drill an alternate hole in the existing crank.  

BrianZ

Nice job, @georgianwinds.
It's a good reminder for those who hadn't seen it before.  In case you're wondering why some of us are chuckling, this idea was documented by @Dalehelman 7 years ago..
https://tab-rv.vanillacommunity.com/discussion/1395/power-tongue-jack-cost-less-than-a-buck/p1
I can thank Dale for the majority of what I  would consider my most used & most valuable mods.  

Basil48192

I made the same modification as JabGopher.  I added a 1/2"Ø set collar to keep the original bushing from falling out.  I also opened up the new 'crank-side' hole to accept a bronze, flanged bushing.  Maybe a little over-kill...but it worked well and I didn't have to re-drill the shaft. 

gulfarea

Trying to drill into a round bolt can be a real pain, what I did to make it MUCH eaizer was to put the bolt in its position right where it should be using its home place to hold i then drilling right threw where the pin goes threw as a guide!  Look at the above photo where he shows the roll pin and play like the roll pin is your drill bit.  This is proberly the best mod I have ever made and as I used the JACK E UP  my bolt head is 90 degreese out so my drill comes in from the drivers side that way drill fits on without hitting anything Art

Slackers

I finally did this mod to the factory jack.  It was easy.