So, back in November I took advantage of the Baja Rack group buy and got one of their full length baskets. Between the group buy, military discount, cash discount, and picking it up in person (no shipping), I scored an amazing deal! :biggrin2:
I drove down on a Thursday morning and installed it in Baja Rack's parking lot.
That said, the install did not go without complications. Whoever the engineer at Toyota is who designed the roof rack mounting points is a guy I'd love to meet just so I could give him a swift kick in the balls. When I removed the stock rack, two of the mounts fell down into the roof liner (you'll see why later). Luckily, I carry a small magnet on an extendable handle in my tool drawer so I was able to retrieve the brackets and mount my rack. However, you are supposed to run RTV around the mounts to prevent leakage and I was not able to do that well (honestly it looked like a drunken third-grader applied the stuff) because I had to hold the mounts in place with needle nose pliers while threading the bolts through the Baja Rack mounting points.
Fast forward a couple of months and SoCal gets hit with more rain than we've had in years. YEARS. Predictably, one morning I got into my 4Runner and was greeted by a wonderful musty smell and a mushy driver's foot-well.
Water was getting in via the driver's side front mount and then running down the A and B pillars and onto the floor. (Good thing my ham radio is not mounted under my seat.) Ughh.
The basic repair plan was to pull up the carpet and dry it out and then pull the headliner down and replace the damn mounting brackets in the roof. I was able to get new brackets and clips from Toyota by the weekend and got a couple of sunny days in a row to make the repairs.
First order of business was to dry everything out. I basically removed the front seats, stripped out everything out from the window line down, peeled back the carpet, and put a fan and a heater on everything. I left it like this for two days while driving the daughter's 4Runner and everything was nice and dry.
Once everything was dry, it was time to pull the headliner and replace the mounting brackets.
Basically, there are two holes in the roof at each mounting point for the roof rack:
One of these threaded brackets then goes into the holes from below (old on left, new on right):
The bracket is supposed to be held in place with one of these clips:
Once I pulled the headliner down, I learned that two clips were completely missing (driver's front and passenger rear), the passenger front clip was almost off its bracket, and only the driver's rear clip was in place the way it was supposed to be. :ybrick:
When I installed the new brackets, I put a drop of silicone on the clips to make sure they stay in place!
View from below showing the holes and the side curtain air bag.
And the new bracket and clip securely in place:
Once the new brackets and clips were installed, I re-installed the roof rack feet before I put the headliner back in place just to make sure there weren't any issues. I ran a nice clean bead of RTV around each white tube and, based on research I did on here, put silicone on the threads of the bolts themselves as well. (One thing I have since learned is that Toyota has little foam rubber washers which should be used instead of the RTV around the white tubes. Next time I guess.)
The rack is now back on and has gone through more and more rain with no further leaks. I'm going to call that problem solved. :biggrin2: