Roof rack install trouble shooting

[vonzippercrane]

hi everyone. You guys were a great help the last time I had problems with my fox coil over I install I figured I give you guys a try again with my roof rack.


I recently removed the stock roof rack to install a front runner rack. My problem is one of the threads on the roof fell inside! I can't get to it. I'm trying to fish it out but no luck so far. This looks like a design flaw in toyotas part.


Any suggestions????

 

[mark71]

You may have to use rivet nuts if you can't fish it out.

Hindsight, I know, but once you loosen the first bolt, don't remove it until you've loosened and removed the second bolt. Otherwise the piece spins inside and is very difficult to line up again.

Many people have made this mistake (myself included). I felt pretty dumb when, after the fact, I saw that the online manual specifically detailed this procedure.

 

[9780LC]

Depending on where it is....you may be able to remove a grab handle from the inside and get to it that way.

 

[619TOY]

I think we should make this a sticky haha...

They can definitely be pulled back out, but it's also definitely a pain in the ass. Things I used to fix the one I dropped into the abyss while learning my painful lesson included an magnet on a stick small enough to fit through the hole, ultra skinny needle nose pliers and most importantly doing this in as dark an environment as possible so you can see into the hole.

I just installed my roof rack yesterday and knowing what I figured out months ago allowed me to complete the project without losing any backing plates. This can help while the mounting is in progress:

 

[vonzippercrane]

hi everyone. You guys were a great help the last time I had problems with my fox coil over I install I figured I give you guys a try again with my roof rack.


I recently removed the stock roof rack to install a front runner rack. My problem is one of the threads on the roof fell inside! I can't get to it. I'm trying to fish it out but no luck so far. This looks like a design flaw in toyotas part.


Any suggestions????

 

[vonzippercrane]

You guys are awesome! I can't wait to get home and try some of these suggestions out.


Ps. Sorry for the misspelling on the original post. I was in the crane operators seat and didn't have time to double check grammar

 

[vonzippercrane]

Depending on where it is....you may be able to remove a grab handle from the inside and get to it that way.

I thought about that but I'm worried about the side airbags

 

[jblatl]

So you installed studs as place holders? That was the pitch and size of the all thread you used? My rack will be in next month.

 

[jblatl]

I must abmit, I am a little intimidated by so many people that have had instillation issues. I am not mechanicaly inclined and plan on installing my New roof rack.

It would be greatly appreciated if you could detail how the parts were lost in the removal process and a rock solid solution for others to take on the future.

Any and all help is very appreciated.

Mark

 

[619TOY]

It would be greatly appreciated if you could detail how the parts were lost in the removal process and a rock solid solution for others to take on the future.

It's really quite simple, the problem is pushing the backing plates, which are on the inside of the roof into the void that is right below them. Think of them as one nut for two bolts. The only thing that keeps them in place is the tension between the yellow plastic rings seen in my picture and the hole in the metal. You can avoid pushing them in by loosening each pair of factory bolts evenly (alternating between the two of them until they're finger loose) and never, and I mean never pushing down on the factory or aftermarket bolts.

 

[linuxgod]

It's really quite simple, the problem is pushing the backing plates, which are on the inside of the roof into the void that is right below them. Think of them as one nut for two bolts. The only thing that keeps them in place is the tension between the yellow plastic rings seen in my picture and the hole in the metal. You can avoid pushing them in by loosening each pair of factory bolts evenly (alternating between the two of them until they're finger loose) and never, and I mean never pushing down on the factory or aftermarket bolts.

Agreed. I was paranoid as well but turning them slowly and very evenly (1 turn each, alternating between adjoining bolts) until they are finger loose and I didn't have any issues. Truthfully once I removed the first set I was more concerned about the feet on the new rack pushing the yellow plastic rings into the void.

 

[mark71]

If you go to 200 FAQ section, post #4 has the "Link to Toyota Service Information Site". Go to this page, click on "Vehicle Exterior", scroll down to "Exterior Panels/Trim", find "Roof Carrier" and click on "Disassembly". The critical step is step #7. Has a nice picture to illustrate the 'single nut' that 619TOY is referring to.

 

[hedd]

The picture below is from another thread, it shows what the nut plate looks like so you can see how it would spin if you loosened one at a time. Additionally, there is thread locker on the bolts which makes it more important to remove the bolts per the procedure. The roof rack is very easy to remove if you alternate as others have suggested.