This is....frustrating. One of the screws on the lower latch of my '96 Roadmaster's tailgate is....tearing. I don't often sit on the tailgate or put weight on it, and it doesn't sag...so why? WHY? I'm thinking of backing out the screw, painting a washer body color, and mounting it there. Any other wagon folks have this happen? -Mike
Definite metal fatigue around the bolt hole...... Looks to me like the latch unit itself might be moving around some - during the 'tailgate down' function. Flatten out the metal area, and I'd suggest using TWO washers - one regular sized, then a big one against the metal to distribute the force over a larger area.
I don't think that's from weight on the door when in the down position. It looks like the metal was thinned out when it was dimpled during the stamping process. Then stressed and broke there. A washer probably would fix it and spread the forces that broke that spot over a larger area.
On those Whales, the metal can get cracked if someone slams the tailgate shut. The force actually tries to rotate the latch on impact. I would suggest getting a body shop to TIG weld the cracks shut, then dress the metal so it's smooth. Then check the bump stops for the T/G, make sure they haven't shrank, which they can do.
I agree with Silvertwinkiehobo. Do it right; get the torn metal welded. Those cracks will continue to propagate if not properly repaired.
Also at least stop drill the end of the cracks to relieve the stresses, then weld or use the counter sunk washers
