broken thread base of roof tube screws?

[DirtySouth89]

2006 Sport Edition with the aluminum tubes for the roof rails.

I unscrewed those T40 screws that secure the roof tubes to the body. First of all, one of the 8 won't come out. It will turn fully, but never rise up. (That seems to violate the law of screws, but whatever I have a different question)

The base of threads that these screws fit into, are like little white cylinders that come up out of the body slightly. On another of the 8, the T40 screw came out all the way but once i pried off the plastic foot of the roof rack, i noticed it was just an empty space left behind. There's no threading for the T40 screw to ever go back into. It's just an empty circle and you can kind of see into the space of the frame of the upper body. Any ideas on this stuff? We are talking the very foundation screw holes of the roof assembly.

 

[DirtySouth89]

the stuck T40

turns (by impact driver) but it's tight as shit and never rises or loosens

 

[AuSeeker]

Unfortunately those "screw holes" are inserts inserted from the inside of the metal roof panel and can only be accessed by removing the head liner, the one that's missing the threads has dropped out of the hole and is now on top of the head liner, the bolt that won't unscrew, the insert is worn out on the outside and is no longer fitting tightly enough in the body hole it's inserted into to be able to get the bolt to loosen.

When you get it all taken apart and start putting it back together be careful not to push any of the inserts that are still in place out of the holes!

 

[DirtySouth89]

It seems crazy that the foundation of the roof rack assembly is anchored by free floating threading, essentially. Sure, that all comes together tight that first time in the factory. But I'm surprised there aren't 500 threads of people wondering how the hell to put the roof rack back on after the bolt housings dislocate and fall into empty nowhere.

 

[AuSeeker]

It seems crazy that the foundation of the roof rack assembly is anchored by free floating threading, essentially. Sure, that all comes together tight that first time in the factory. But I'm surprised there aren't 500 threads of people wondering how the hell to put the roof rack back on after the bolt housings dislocate and fall into empty nowhere.

There are at least a couple of topics on this subject/issue, that's how I knew what to tell you.

If I recall correctly in one topic I think the OP says there are little clips that hold the inserts in place but dislodges or breaks easily...but it's been awhile since i read that topic so I could be wrong, I do however remember he removed his head liner and secured them much better.

I think the reason you don't read more about this is because there's not that many who remove and or replaces their factory roof rack and the ones that do don't always have this issue, so the issue is not all that common.

 

[DirtySouth89]

...I think the OP says there are little clips that hold the inserts in place but dislodges or breaks easily...but it's been awhile since i read that topic so I could be wrong.

You're definitely not wrong here. I'm a testament that this is exactly correct. The mere act of unscrewing these incredibly tight T40 screws broke/dislodged the thread clips or whatever you call them. Broke 1 of 8 and another broke while the screw was still partially in so it can neither be removed nor tighten back the rest of the way.

 

[randy88fj62]

I hate the design used for the threaded inserts used on the 4Runner. I have no confidence in the roof rack when loaded up. Many times I have considered drilling more holes in the roof to secure additional mounts, especially up in front of the existing ones so I can fab an extended roof rack.

My old landcruiser has rain gutter rails and I love the simplicity of the system.