Hey all so I've searched through forums and youtube and what i feel like is the whole internet for help but no one seems to have my problem with the tailgate. So for my 2nd gen 4runner, the tailgate window regulator is completely rusted through (i guess there was a leak in the weatherstrip at the top at some point). I'm familiar with all the problems with the wiper arm etc and fairly confident i've tested all of those. I've disconnected the motor to test that it works when the switch in the centre console is pressed (it does work), and my issue seems to be that when the window motor is attached, the regulator mechanism is so rusted that the motor can't move it. I've tried all sorts of penetrating agents to try and free it but to no success. I've got a replacement regulator but I seem to have got myself in a bit of catch 22.

The window is fully up. I can't seem to open the tailgate because the window is fully up. I can't move the window down because the regulator mechanism is so shot. I can't replace the regulator with the window being up. Everyone online seems to say that to remove the window from the regulator arms the window must be halfway down to slide the arms off...

How on earth do I proceed? I thought perhaps I could try and disconnect the window with tailgate up but i don't wan to risk breaking the window. I've taken all the panels off and understand how the mechanism prevents the tailgate from opening and i've manually operated it, but I still can't get it open. Any help would be greatly appreciated. I'm going to give it another go tomorrow and can send pictures but thought i'd try and get some suggestions before tomorrow.

 

Crawl inside the back.
there are 3 screws that hold the motor on the regulator. Remove those 3 screws and take out the motor and you'll be able to lower the window.

 

By hand? The gear-like sprockets that rotate to lower the window are seized so the regulator arms won't lower

 

if you still can't lower it...
You can now access the 4 bolts that holds the regulator to the tailgate.... then drop the whole assembly down enough to seperate the glass from the regulator and remove them both.
Viola!

 

Peachy, you may be able to apply more leverage than what the motor can.
with the motor disconnected try to force the arms down, find a good pry point and see if you can work it down.
otherwise I think you will have to cut the arms off above the regulator, just make sure the glass can't just drop and possibly break it.

 

Still no success, I undid the 4 bolts that hold the regulator in place, but without the window down a little bit theres just no manoeuvring room. I thought about cutting the regulator arms as you say which may have to be the case, but i also noticed that the rollers on the end of the arms and the channels they sit in are also rusted through and seized, so I'm thinking thats also when the regulator won't move, either way i'm going to have to get some new runners for the bottom of the glass. When I say the runners are rusted through I mean crumbling under my touch kind of perished. But for now the plan is find some runner arms somewhere and then cut the old regulator out.

Also no matter what I do I cannot seem to get tailgate to open, does the window being up activate some sort of electronic lock on the tailgate? I can't see anything that's preventing it from opening, I was trying to pry the cables and even move the tailgate latches myself, but it just doesn't seem to want to budge. Very frustrating morning fighting with it.

 

Making headway?

 

If all else fails get out a trust cut off wheel.