Removal of factory roof rack
 

I have a 2000 model with the factory roof rack and cross bars. The paint is peeling off the roof rails and I would like to remove them and have them powercoated.

I checked the rails and there are some bolts in the tracks. Would this simply unscrew from the roof. Are these threaded holes or are these self tapping screws?

Thanks.

My 2000 has the exact same issue but I haven't got around to repainting yet.

I do know that there are roof rack support/reinforcing panels inside the roof, so I assume they will have fixed nuts that the bolts you can see will screw into.

I've actually been working on this over the weekend. My cross rails were gray and my side rails didn't even have paint on them anymore and looked like crap. I had to move the tall cross bars at front and rear to reveal the torx screws that keep the end caps on. Then the end caps just pull out. Then I removed all the cross bars and removed the rest of the torx screws. They are threaded holes too. Unfortunately, I'm pretty sure this is the only time the bars and tracks have moved in 10 years and I uncovered the nicely stained paint underneath :moping:. It is easy to do. Hope this helps some.

What size torx bit did you use? I am going to remove mine soon to polish/wax the roof.

Bumping this old thread for my factory rack related issue.

I removed all my cross members to install my Thule rack a few months ago. Of course I broke the plastic end caps, but figured I'd wait to replace them until I had to make a trip to the dealer for more than 2 $5 parts.

Problem is....
I really thought I replaced the torx screws, but being up there to wax the other day I noticed i had not in fact put them back in place. Now I'm worried that after 4-5 snow events and some rain, I've got water in between my roof panel and headliner. Anybody know if the holes go all the way through? If so, do I just wait for a week of sun and heat to bring out the moisture, or would I have to drop the headliner? Just looking to avoid a rust issue.

I think those endcaps were more like $10 or $15

I believe the water would leak through and/or you would hear a sloshing noise if it was trapped up there. I think you're fine if you haven't noticed any leaking through the headliner already just put the bolts back in. I used some black silicone to ensure mine wouldn't leak.

What size Torx? I don't have any, and I need to know the specific size before I borrow one from my mechanic.

t25h or regular t25

I was considering removing the crossbars that sit directly against the roof to clean up the look a bit but am also worried about the altered appearance of the paint that has been under the bars all this time.

I know what you mean. I faced the same issue when I removed them. But some good polish/paint treatment helps, even if it won't completely remove the effect on the paint.

I took mine completely off and mounted my rack straight to the roof. *shrug*


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I got rid of the crossbars and got a rhino rack pioneer platform. Best decision I've made as far as roof racks go.

I did the powdercoating a few years ago and remember a few things.
1. Those end caps are not cheap - be very careful or just go to junkyard ahead of time
2. Between the body and the frame are small washers that the torx screws go thru. Toyota does not sell these anymore. I bought some small rubber washers from Lowes to use in place and used silicone rubber on both sides and on the screws to keep water out.
3. Take a picture of which direction the main cross supports go or you will have to take them off (again messing with end caps) and reverse them
Powercoating was about 100 bucks around 2012

Roof rack Torx screw filled with metal.
 

I’m trying to remove my 1999 factory roof rack. I’ve got leaking in my A-Pillar and the headliner around the visor. I’ve checked all the sunroof drains and they appear to be clear (hard to tell with the rear ones as the weed eater line wont’ go all the way up but I blew compressed air through and it seems to flow). I think this might be the first time the rack has been got at. All the Torx screws came out fine (they were in their good and tight with silicon) except one. For some bizarre reason the “slot” (where the screw driver bit goes in) is filled with some kind of impervious metal. Like it was melted by Vulcan himself and poured in. We’ve tried metal drill bits, chisels and punches and nothing even scratches it. Is this by any chance something the factory might have done? Any idea how I can get that Torx screw out? Also there were four square holes, one at each end of the rails, with plastic tabs in them but no screw from the rack rail. I filled these with silicon. Any idea what they’re for? Thanks.

I have a smallish problem with one of the roof rack bars, there is a bit of rust with a hole through the roof metal that is the size of a grain of rice. Likely the rust has spread INSIDE the roof metal and I'll have to remove the headliner to get at it. No problem for me to grind out the rust, prime and paint it but dropping the headliner is a job I'm not looking forward to. Old plastic clips very likely to break . Grr !