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Pop N Lock PL8521 Install With Emergency Release

Discussion in '2nd Gen. Tacomas (2005-2015)' started by ACEkraut, Aug 14, 2016.

  1. Aug 14, 2016 at 9:46 PM
    #1
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    Aaron
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    I am not looking to recreate the wheel in regards to installing the Pop N Lock PL8521 since there is a long thread with many installation details:

    https://www.tacomaworld.com/threads...gate-install-2012-tacoma.214928/#post-4915955

    One of the complaints that many PL8521 owners have is of the unit failing in the locked position causing various amounts of frustration in getting the tailgate open, particularly if you also have a locking tonneau cover. The picture below illustrates my solution to the potential problem.

    542EBD7A-EE70-44E1-B27D-52ABA66BBD51_zps_4b7a9c05e243b5088b562726836753e092dd9cf0.jpg

    My solution is simple, easy, cheap and installs quickly. I took some leftover cord, tied one end to the locking bar on the PL8521 and then, leaving a little slack in the line I ran the other end out the drain hole just below the unit. Then I looped the excess around and over the tailgate leaving it inside the tailgate. Next I put the tailgate cover back on, pinching the cord in place but leaving a hidden cord under the tailgate hidden from view. If the PL8521 ever fails I can grab the cord and pull, manually unlocking the tailgate. The cord cannot be seen from the back of the truck unless you are on the ground looking up from under the back of the truck.

    Here is the completed installation without the tailgate cover on.

    8BF9EFDE-C153-4C4A-AC01-0654C8EA113E_zps_0911c2e3f362e1006e3f0eb53e6d838c983e6bd3.jpg

    And I found out it works as I accidentally closed the tailgate in the locked position with the tonneau cover locked in place. One quick pull and it was unlocked.
     
    Last edited: Aug 14, 2016
  2. Aug 16, 2016 at 11:10 AM
    #2
    DRP6833

    DRP6833 Well-Known Member

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    I like this idea, next time I'm working on my truck I'll add this. Thanks!
     
  3. Aug 16, 2016 at 4:02 PM
    #3
    caribe makaira

    caribe makaira Well-Known Member

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    How would this be incorporated if the handle broke?
     
  4. Aug 16, 2016 at 8:18 PM
    #4
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    You bet!
     
  5. Aug 16, 2016 at 8:23 PM
    #5
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    You are describing a different problem that this solution would not work on. About the only thing you could do if the handle broke would be to take the tailgate cover off, manually release the tailgate then fix the problem.
     
  6. Dec 15, 2016 at 4:38 PM
    #6
    Tacotoya

    Tacotoya Member

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    Brilliant. This was a big concern of
    Mine. This site is awesome. Thank you
     
    Marc70 likes this.
  7. Dec 15, 2016 at 4:56 PM
    #7
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    Glad to help. One person improved upon my idea by tying off the end of the cord inside the tailgate skin so it cannot come undone and when you pull you can only pull the cord in the direction that will unlock the lock.
     
    Marc70 likes this.
  8. Dec 17, 2016 at 5:42 PM
    #8
    yeos

    yeos OCD Member

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    Never thought it would happen to me, but my 8540 latch broke today in 20 degree weather just after I high sided in the snow. It lasted two years. Going to have to find a way to lower the gate and remove the pop n lock. I just viewed this thread two days ago too.
     
  9. Dec 17, 2016 at 9:41 PM
    #9
    taco-man

    taco-man Well-Known Member

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    I did that but i didn't share sorry guys, now i know how to open your tailgate, whats your plate number again Lol
     
    ACEkraut [OP] likes this.
  10. Dec 17, 2016 at 10:12 PM
    #10
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    Get a coat hanger and bend a hook in it and slide it up through the center drain hole and hook onto the solenoid and pull down. Use the pictures above in this thread to help you figure out where the solenoid is.
     
    Tn Jeff and yeos like this.
  11. Apr 6, 2019 at 4:18 PM
    #11
    Guitarman

    Guitarman Member

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    This is a great idea but be careful about the cord hanging down. Anybody can climb under the bumper and give a pull and they have unlocked the tailgate. Try to hide the cord end.
     
  12. Apr 6, 2019 at 6:42 PM
    #12
    ACEkraut

    ACEkraut [OP] Well-Known Member

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    If you put the extra cord back into the next opening over and the cover pinches the cord then the cord will essentially be tucked up tight under the lip of the tailgate and it cannot be seen unless you get up close and look under the tailgate.
     
  13. Apr 6, 2019 at 7:50 PM
    #13
    steveo27

    steveo27 Ask me about my weiner

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    The same shit everyone else has.
    I’ve had a piece of paracord off my pop n lock like ACEkraut described for 5 years now and it’s been fine.
     
    mikalcarbine and ACEkraut [OP] like this.

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