Can you reinstall roof rack when factory holes filled with sealant?

Toyota took off Forerunner Slimline roof rack due to leak and extensive water damage. In doing so, rather than restore it to normal with factory tape to cover holes and replace trim, they filled all the factory holes with sealant. They refuse to reinstall the roof rack since it is aftermarket. They also refuse to warrantee the sealing repairs against further potential water damage. Since they have filled the factory holes with sealant, am I going to be able to safely reinstall the roof rack? Will I have to remove all the sealant and replace with new or can I just drill safely through the sealant and add more? I fear the holes could have been damaged by repairing it like this. The leak resulted in severe mold and a damaged air bag which had to be replaced for about $2000. I don't want to go through this again but I do need a roof rack. Please advise about the viability of drilling through the sealant or other options. Thanks

 

Depends on what they used to seal it with. I’d start with a Dental pick and dig it all out.

 

Yes, carefully drill through sealant with small diameter drill bit, and then run a tap to clean threads. Take your time doing so.

 

So to reinstall, you need to totally remove the sealant in the factory drilled holes by either drilling them out or digging them out with a dental tool. Correct? When you say run a tap, do you mean run water? Will that clean out the sealant? Sorry, I am not DYI. Do you also have to add new tape?

 

Tap is like a drill bit with threads on it, it can be used to clean the holes out. When I installed my rack, I used silicone around the holes / thread and installed the bolts. No leaks as far as I can tell.

 

hopefully they just used a silicone sealant. If so, just carefully pick it out. When you do reinstall the roof rack, make sure you apply more sealant to make sure you don't end up with the same water damage as before.

 

Oh yeah

 

Tap as in a thread chaser. You will have to out what size and thread pitch those insert are. Take the bolts to hard store and match up what size tap to purchase.

 

I’d be reluctant to drill out the sealant, as the chance for real damage to the threads seems significant. Sealant alone won’t damage the threads.

When you say sealant, is it of a hard or soft consistency? Hard would be some type of butyl or mastic (I’d be pissed). As others have said, if it is silicone (soft), pick it out until you are able to thread in a mounting bolt.

 

I feel your pain on this one. Installing and removing a roof rack was a massive headache for me because of the leaking factory holes as well. Biggest/only mistake I’ve made with this truck.

I can’t help with any knowledge about reinstalling a roof rack (I just re-sealed the holes after removing the roof rack) but I hope you find a solution that works.

 

Not sure why some here are busting the OP's balls for stupid "Friday thread"? Sounds like this is a legit issue for him that he is just asking for some help here.

Just dig out the old sealant as best you can OP and then go from there. And maybe consider covering the screw holes with some of that Gorilla sealing tape. That stuff is crazy good.

 

What was the cause of the water damage? Was your rack installed Improperly? Did you pay out of pocket for the repair or was it covered under warranty?

if you paid out of pocket for repair, I’d be pretty pissed as you’re paying for the repair. Telling you what you “get” when it’s your money is annoying.

however if it was warranty work, it’d be a little different.

 

Yep, seems like a legit question. Some people just like to be asses, and contribute nothing.

Also, OP try not to use any solvents. Most that would dissolve silicone would harm the paint.

 

Drill new holes? Self tapping screws and lots of silicone? Weld it on? 3m tape, cuz that stuff is amazing!!!!