Should I Remove the OE Roof Rack

[BTLSHP]

Whether you remove the rack or not is a personal decision; I can't offer any useful opinions there. Your A pillar leak is the sunroof. The front drain hose is not draining causing the pan to fill up and run down the A pillar.

Pulling the drain plugs in the rocker panel, cleaning the drain tubing and pinch welds will not solve this problem. All that may help, but the problem is in the drain design.

The permanent solution is to run the drain hose through the floor. You can either a) use the floor hole Toyota provided under the floor mat (not my choice), or b) remove one of the body panel screws securing the rear edge of the fender to the body and drill out the weldnut in the floor of the well to allow you to run the hose through it.

You can either a) use a smaller/larger diameter hose to extend the hose, which doesn't currently reach the floor of the well the harness is tucked into, and into which the sunroof drains, or b) swap the front drain with a rear drain. Same size, extra 12" longer; it'll get through the floor of the well and extend about the same amount as the current rear drains do in the rear fenders.

Ok, this is the first idea that meshes with my limited appraisal of the leak. I am going to have to look at a schematic to get a better handle on your suggestion. I like it. Thank you for taking the time.

Funny, this thing spent the first 24 years of its life in Old Town Alexandria

 

[fjbj40]

Looks way better without…..

 

[BTLSHP]

Looks way better without…..

View attachment 3428843

I agree, but that has to wait for another day.....$$$. It will eventually become a rock climber's vehicle and need a real rack to support a roof top tent.

 

[BTLSHP]

I went under the car today and realized why Malleus said zip tie and not bamboo skewer..... my sense is the drains are mostly open but for now I am going to pull out on of the plastic plugs to be safe. Have to think about winter time. I am sort of guessing one problem over time is the seal on the sunroof is less elastic and admits more water.

I was really surprised with the size of the rear drain hoses. Far bigger than I imagined.

I will get some new hardware and Clear Bra for the roof rack.

 

[brockdeck]

I went under the car today and realized why Malleus said zip tie and not bamboo skewer..... my sense is the drains are mostly open but for now I am going to pull out on of the plastic plugs to be safe. Have to think about winter time. I am sort of guessing one problem over time is the seal on the sunroof is less elastic and admits more water.

I was really surprised with the size of the rear drain hoses. Far bigger than I imagined.

I will get some new hardware and Clear Bra for the roof rack.

Note that the sunroof is designed to essentially let water into the pan and then drain it out of the pan. If the drains are blocked, thats when it leaks. Now if it is coming through regardless thats another problem.

 

[BTLSHP]

Note that the sunroof is designed to essentially let water into the pan and then drain it out of the pan. If the drains are blocked, thats when it leaks. Now if it is coming through regardless thats another problem.

Okay, I have poured a quart in at each drain and it seems to run through. On the passenger side there was dirt in a couple of the gaps that drain the rocker area. I have very thin maybe 1/8" diameter plastic tubes I use for threading wires through bicycle frames. I ran a 2m length through each of the four drains pretty much without resistance.

The leak happened after about an hour's downpour, we got in and headed back home. We saw the wet spot appear 10 minutes into the drive. It seemed to be "clear" water not water with rust in it if that makes sense.

 

[brockdeck]

Okay, I have poured a quart in at each drain and it seems to run through. On the passenger side there was dirt in a couple of the gaps that drain the rocker area. I have very thin maybe 1/8" diameter plastic tubes I use for threading wires through bicycle frames. I ran a 2m length through each of the four drains pretty much without resistance.

The leak happened after about an hour's downpour, we got in and headed back home. We saw the wet spot appear 10 minutes into the drive. It seemed to be "clear" water not water with rust in it if that makes sense.View attachment 3429815

Have to wonder if the drain tube is disconnected in any way. Another possibility is the windshield gasket leaking.

 

[BTLSHP]

The windshield was replace by Safelite. I am not certain the followed Mr. Toyota's process, but I watched the bead of sealant get laid down. It seemed continuous and began and needed on the driver's side down low.

 

[brockdeck]

The windshield was replace by Safelite. I am not certain the followed Mr. Toyota's process, but I watched the bead of sealant get laid down. It seemed continuous and began and needed on the driver's side down low.

So I also had my windshield replaced by a local company, (great guy by the way, he owns an 80), but unfortunately it did leak in the first couple weeks.

They had come to replace my windshield gasket, and upon removal my original windshield cracked. They felt terrible, supplied me with a new one and a gasket. Well, they didn't remember to apply sealant to both sides of the gasket. The way the 80 windshield sits, it requires sealant on each side to avoid a leak. This is highlighted in some threads here as well as the FSM. I would definitely check that out.

 

[BTLSHP]

So I also had my windshield replaced by a local company, (great guy by the way, he owns an 80), but unfortunately it did leak in the first couple weeks.

They had come to replace my windshield gasket, and upon removal my original windshield cracked. They felt terrible, supplied me with a new one and a gasket. Well, they didn't remember to apply sealant to both sides of the gasket. The way the 80 windshield sits, it requires sealant on each side to avoid a leak. This is highlighted in some threads here as well as the FSM. I would definitely check that out.

Ugh! I will go look at the FSM. But I absolutely recall the process Safelite used - a single bead.

Thanks for the heads-up

Yeah, Safelite did not do anything like the manual

 

[brockdeck]

Ugh! I will go look at the FSM. But I absolutely recall the process Safelite used - a single bead.

Thanks for the heads-up

Here is a thread, post #6 has a link with the FSM

80 series windshield replacement -FSM

Is there a section in the FSM for replacing the windshield? I had mine replaced a week ago and it’s leaking. I don’t have the manual, was hoping to just grab the pages I need.

forum.ih8mud.com

 

[BTLSHP]

Ok, so last night it was parked with the front end slightly below the rear on a sloped drive way. We had several torrential downpours through the morning. Enough so that I could watch water sheeting across the sunroof and along the gutters.

No leaks inside, so I am guessing this points at the Satellite windshield install of a few years ago.

Question: Where would I go to find someone willing to follow the FSM in installing a new windshield?

 

[BuzzAZ]

Unless you’re willing to drive to Phoenix I don’t have a specific suggestion for you, but I would search for local shops with only a location or two that have been around for a while and have good reviews on Yelp/Google.

 

[BTLSHP]

Unless you’re willing to drive to Phoenix I don’t have a specific suggestion for you, but I would search for local shops with only a location or two that have been around for a while and have good reviews on Yelp/Google.

I am sort of wondering whether I can rely on a dealer to follow the FSM? Or do they cut corners to save time

 

[BuzzAZ]

If it’s the dealer that actually does the work, I imagine they would. Dealerships I’ve dealt with in the past have used a third party for glass work.

 

[BTLSHP]

That is my worry, going to the dealer does not ensure the FSM procedure is followed.