Encountered this today as I was replacing a stock roof rack bar. The primary fasteners which hold down tracks and serve as a stop on the ends would not tighten back down sufficiently, leaving a small gap between surface of roof and track. I figure if I don't fix this it will leak water inside. I've searched the threads here but didn't find anything, I apologize beforehand if this is a repeat. The torx head screws will not tighten. I'm thinking whatever setup for a threaded locking mechanism beneath was either originally potted in place with glue or badly welded. Any suggestions as to a good, quick fix? Tomorrow I'm planning on taking the entire rack-track assembly off and going over it.

 

I have the same prob. I had to tack the threaded fitting to the roof. Its just pressed in i believe and to much torque on the bolt will break the fitting loose. If ya can't weld, hold the fitting with some pliers and tighten the torx head. Just snug it though.

 

 

I did a little more research and found this. It may be useful.

http://www.amazon.com/M6-1-0-Well-Nu...ews/B0040CZ3R4

 

http://www.tek-ed.com/tek-ed/rrack.html

and yes ... I have plenty of time on my hand ... ha.

 

^^ thats way to much for me too read but im sure the guy knows what he's doing.

 

Update: I removed both tracks and discovered about 8 of the 10 inserts were bad. Explains a lot of the rattling noises overhead and why this rig had no headliner at'all (leaks). I went to Ace Hardware (only game in town) and found some standard sized well nuts that would fit the rather enormous looking OEM holes (about 1/2" diam) but alas they do not expand when the screws are threaded in, as they need to. Next step, after work tomorrow am checking into riv-nuts, something akin to what was described in the last link above. They're suppose to expand when you thread them ... as to fill the hole and subsequently seal it. All this was no concern to me before I replaced the headliner ... ha.

 

good luck.