Tailgate Assist-Problems installing
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Paint is not the issue. The trucks are painted after the screws are installed, and the paint layers are very thin. The screws are precoated with threadlocker (the pink material in the photos cajun4x4 posted). They are also highly torqued during installation (I've forgotten the exact number, but I believe it's around 70 ft-lbs).
A penetrating lubricant definitely helps during removal, but they still take a lot of initial effort to break them free.
It does look like the OP's screw was cross-threaded during installation, but it appears that there is still enough meat in the bracket to hold the screw after chasing the threads with a tap; it's definitely worth a try. I'd use a torque wrench to tighten the screws to be sure they will hold the required torque value (I'm thinking 50+ ft-lbs).
A penetrating lubricant definitely helps during removal, but they still take a lot of initial effort to break them free.
It does look like the OP's screw was cross-threaded during installation, but it appears that there is still enough meat in the bracket to hold the screw after chasing the threads with a tap; it's definitely worth a try. I'd use a torque wrench to tighten the screws to be sure they will hold the required torque value (I'm thinking 50+ ft-lbs).
I was able to chase the threads. Luckily one of the teachers I work with teaches industrial maintenance and had the correct size. It was 10-1.5. Tapped the hole and was able to get everything buttoned up. According to the install instructions from Ford, the correct torque value is 55Nm or 41 lb-ft. Thanks again.
