Roof Rack Sealant? Need Advice

Butyl tape is another option for sealing. It stays flexible and if you have to redo it you won't have the silicone to deal with. It's simple to use and has a great reputation having been around a very long time.
 
This thread got bumped at the perfect time. I discovered a puddle in the driver's side of the cargo area yesterday, in the little cubby above the wheel well. The headliner's only wet above this area, so I'm suspecting the factory roof rails vs. moonroof drains. Anyone else had issues with the factory setup leaking? I'm the 2nd owner, and as far as I know, they've never been removed.
 
This thread got bumped at the perfect time. I discovered a puddle in the driver's side of the cargo area yesterday, in the little cubby above the wheel well. The headliner's only wet above this area, so I'm suspecting the factory roof rails vs. moonroof drains. Anyone else had issues with the factory setup leaking? I'm the 2nd owner, and as far as I know, they've never been removed.

The factory mounts use just a "foam washer" between the foot of the rail and the body, so they can easily deteriorate over time. It is so easy to take the rails off and add some sealant in place of those foam washers.
 
The factory mounts use just a "foam washer" between the foot of the rail and the body, so they can easily deteriorate over time. It is so easy to take the rails off and add some sealant in place of those foam washers.

That's what it looks like. I took apart the trim in the cargo area and poured water and indeed tracked it to the rear driver's side mount. I've got the rails removed now, just debating whether to replace the factory parts or try something else.
 
I used butyl rubber tape around the mounts when I had my roof rails powder-coated. "3M Windo-Weld Round Ribbon Sealer"
 
Butyl tape. McMaster Carr sells rolls of it and it can be removed without damaging the paint. It's the same stuff that Toyota used in the first place.
 
Butyl tape. McMaster Carr sells rolls of it and it can be removed without damaging the paint. It's the same stuff that Toyota used in the first place.

Didn't see any of that on mine, just the parts listed here. 63437A is the part number that needed to be replaced. And they definitely damaged the paint. I found them for $0.50 + $15 shipping, or $5 a piece at the local dealer...

Instead, I scored some neoprene washers and Permatex Ultra Black from Home Depot and went to town. Once it's done curing tomorrow afternoon I'll give it a test, but I'm pretty confident.
 

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