Pop N Lock Tailgate Lock Revisited
Spent 2 hours this afternoon installing a manual Pop N Lock tailgate lock on my 2001 Flare side. I had read all of the threads about this unit being poorly designed, not working, or being difficult to install and operate.
I discovered that the installation of this product is not a 15 minute no-brainer. If you want a good install you will have to pay attention to clearances especially that of the cylinder lever and the screw that retains it.
I had to grind a relief in one of the stud heads to clear the cylinder lever retaining screw to allow the key to turn freely. I also had to use washers between the tailgate handle bracket and the Pop N Lock assembly to get proper clearance for the cylinder lever to clear the tailgate sheet metal in the unlocked position. In addition, I had to file the cylinder lever shorter to allow it to enter the slot in the tailgate handle in the locked position.
I probably had the assembly on and off the tailgate a least a dozen times before it operated smoothly like a lock should. Is the Pop N Lock a great product? No, it isn't great, but if it is properly installed it will work as it was designed and it will provide enough security for your tailgate to deter casual theft. If someone really wants access to your truck there are few devices that will insure perfect security.