2004 100 series original roof rack replacement

[Goose04]

I just purchased a 2004 Toyota LC, the roof rack caps were missing so I ordered what I thought were factory roof rails to replace them.

Now I have removed the old roof rack and the replacement parts do not line up with the previous rails. Appears I ordered the wrong part. Previous owner had replaced the caps and they had just come off again, not looking to do an aftermarket overlander rack but are there any simple solutions to the original parts would prefer to avoid replacing the rain gutters?

Original:

Fit for new rails:

 

[Super77]

Unclear what the problem is, other than “replacement parts do not line up.” Be more specific?

 

[Goose04]

Unclear what the problem is, other than “replacement parts do not line up.” Be more specific?

Sorry, I expect this gap will be an issue causing water to drain into the cabin. Can’t find the original part listed except used with missing caps as well. Is there a part I’m missing to close this gap, do I have to replace the whole rain gutter?

 

[Super77]

Still not really following the issue with the rack, but the trim strip that covers the rain gutter is not a water seal. Water that gets under the trim just flows out the back. Think of it as a controlled leak. The water intrusion seal happens at the M8 screws holding the rack against the roof. Use a dab of good butyl or polyurethane sealant on the upper threads of the bolts.

For slicktops, Toyota makes little plastic filler panels that cover up the rectangular hole in the rain gutter trim that is left over when the rack is removed. Check the parts diagram on partsouq.

Also, make sure you use original shoulder bolts to fasten the roof rack. If they are rusty, give them a good cleanup with a wire brush. The white rubber sleeves above the threads help with sealing.

 

[Goose04]

Thank you, I guess the gap is not a problem then except for looking funny from the top. Appreciate your info.

 

[Super77]

Thank you, I guess the gap is not a problem then except for looking funny from the top. Appreciate your info.

Cover them with black duct tape to keep debris out, or spring for the little plastic fillers pieces from Uncle T.

 

[jaewastooshort]

if the issue with your original rack was just the missing caps, could you not just put the caps from the "new" rack on your original? maybe I misunderstood the original issue.

 

[Malleus]

No, Toyota, for some unexplainable reason, felt the need to make every 100 series year model rook rack unique. I'm almost at the point where I'm goign to use my one good cover to make a urethane mold for an opposite hand cover. Not the arts and crafts I ever wanted to get in to, but I can't stand the way the skeletor rack foot looks.

Can't somone make replacements? Please?

 

[Super77]

I’m wondering what the OP means by “cap.”

 

[jaewastooshort]

from his post:

Cap on left, no cap on right. It's just a plastic cover that goes over the mounting feet to give a more sleek line to the rack.

 

[Super77]

No, Toyota, for some unexplainable reason, felt the need to make every 100 series year model rook rack unique.

I’m not sure the factory rack was Toyota. I’ve never seen it in the parts diagrams, has anyone else? I thought I remember reading that it was a port-installed option that was ticked for 99% of North America but not for all of Global?

 

[Malleus]

Possibly. That would explain a lot.

 

[Super77]

Possibly. That would explain a lot.

Yeah the bolts are unobtanium but a correct install depends on them.

 

[Goose04]

Yes the caps is exactly what previous poster said. I’m also having trouble finding the original rack- I’m curious if previous owner put a 200 series rack on the 100 but I don’t know. My LC also has 2013-15 200 series wheels so it seems they may have mixed and matched a bit. Or are these wheels oem stock?

 

[Goose04]

It kind of appears that the rain gutter was cut to fit the current broken roof rack.

 

[nakman]

Yes the caps is exactly what previous poster said. I’m also having trouble finding the original rack- I’m curious if previous owner put a 200 series rack on the 100 but I don’t know. My LC also has 2013-15 200 series wheels so it seems they may have mixed and matched a bit. Or are these wheels oem stock?

It wouldn't really be possible to put a 200 series rack on a 100- aside from the length/width differences, the bolt spacing on the 200 is a lot narrower, so the holes just wouldn't line up.

Also your concern about the missing cover and water is valid, but pretty unsubstantiated. Those little covers, and the entire channel cover for that matter, get tossed out pretty quickly over here- unless the truck is a garage princess, there's often a good amount of debris found in there when the original rack is removed. Here's an example of an install I did yesterday:

And what made this one even more special was the rusted Torx screws on the middle towers- that particular OEM rack has a great way of capturing water, literally eroding away any usable amount of the torx head. Only way to get it off is to hack up the tower with the angle grinder, then grind away enough of the bolt head to where you can grab it with a big vice grip. I didn't take pics of that but you can see the burned spot on the moving blanket, not the first time I've done this. or 2nd, or 3rd.. it's becoming more and more common as the less babied 100 series trucks change owners and become modified.

But there's a reason we don't try to replace those covers, or preserve that channel cover. that reason is pictured here. The bolts in the channel are all sealed well so no water gets in, and your windshield is sealed also... the rest is cosmetic.

 

[Super77]

It wouldn't really be possible to put a 200 series rack on a 100- aside from the length/width differences, the bolt spacing on the 200 is a lot narrower, so the holes just wouldn't line up.

Also your concern about the missing cover and water is valid, but pretty unsubstantiated. Those little covers, and the entire channel cover for that matter, get tossed out pretty quickly over here- unless the truck is a garage princess, there's often a good amount of debris found in there when the original rack is removed. Here's an example of an install I did yesterday:

View attachment 3960879
View attachment 3960880
View attachment 3960881

And what made this one even more special was the rusted Torx screws on the middle towers- that particular OEM rack has a great way of capturing water, literally eroding away any usable amount of the torx head. Only way to get it off is to hack up the tower with the angle grinder, then grind away enough of the bolt head to where you can grab it with a big vice grip. I didn't take pics of that but you can see the burned spot on the moving blanket, not the first time I've done this. or 2nd, or 3rd.. it's becoming more and more common as the less babied 100 series trucks change owners and become modified.

But there's a reason we don't try to replace those covers, or preserve that channel cover. that reason is pictured here. The bolts in the channel are all sealed well so no water gets in, and your windshield is sealed also... the rest is cosmetic.

Can confirm that the center tower bolts are the weakest point of the OE rack design. They sit in a little well that fills up with water, so the torx bolt heads sit immersed most of the time. There should be a better drainage means in that well, but without maintenance, that would probably get clogged up. Nobody ever checks these things.