Waterproofing Roof After Roof Rack Removal

The roof of my 2021 SR5 has been leaking since I removed my Prinsu roof rack. I’ve filled the pre-drilled holes with rubber push screws and sealed those with commercial grade silicon.

Unfortunately no matter what I try, the headliner above the A-pillars is still soaked and drips onto me and the passenger when it’s raining. I never had this issue before I removed the roof rack so I have no reason to believe there is any issue causing this other than the missing pieces of rubber on the roof.

At this point I am going to just replace the entire weather stripping on both sides.

I’ve located the parts and part numbers for the left and right side weather stripping.

My question(s):

Do I need anything else? Are there any type of screws or plugs that are installed in the pre-drilled holes from the factory that I will need to also order?

I had a professional shop install the Prinsu and they threw away literally everything besides the roof rack itself when they were done, so I have no idea what (if anything) was under the weatherstripping before the roof rack was mounted.

Thanks in advance.

 

I would use a piece of vinyl and silicone it down and then cover the top of it with more silicone. From the factory there is a piece of tape they use to cover the holes. You want to try and replicate. The roof moulding isn’t meant to create a waterproof seal.

 

Tyr the flex seal tape. Cut it to size. That is some strong stuff and will fix your issue. Make sure you didnt develope a 3rd brakelight leak. Good luck!

 

Thank you guys! I’ll just dig out all the silicon I’ve put down and do what you both suggested.

and yeah, I’ve read about the third brake light leak and I’m really hoping that’s not the issue.

 

Use butyl tape. I've used it for years constructing campers.

$17 Dicor BT-1834-1 Butyl Seal Tape - 1/8" x 3/4" x 30' Repair Tape for RV, Trailer, Motorhome, Window, and Vent Sealing

https://www.amazon.com/Dicor-BT-1834-1-Butyl-Seal-Tape/dp/B001FCB4JS?th=1

 

That looks like a great idea.

I know the rubber weather stripping itself isn’t supposed to be waterproof, but it is safe to say that any water that enters the pre-drilled holes would leak into the cab?

If that’s the case, it blows my mind that Toyota would only use a small piece of tape to cover each hole under the weather stripping.

 

In addition to above suggestions, would it be worthwhile adding some of these allen head screws to the existing threaded holes? Maybe add some thread sealer?

 

The above suggestions are spot on, but to add to these, prep... clean off the old silicon. Then clean the area with rubbing alcohol with a lint free cloth before applying anything. If it isn't perfectly clean, it won't seal.

 

Thanks for the suggestion! I actually put a solid plastic thumb screw into each hole and then sealed over top of it with silicon.

That’s why I can’t figure out how the water is getting in…the holes are filled with plastic screws and then I sealed each one in with silicon. So it should be totally sealed.

 

^^This^^

I drilled holes (for rivets) in my ditch channels in addition to using the factory threaded holes to install my roof rack. Butyl pads were supplied with the rack. No leaks after 3+ years.

 

The suggestion for the set screws is a great idea. Placing silicone on the threads, screwing them in, placing a layer of butyl tape the length of the track and then installing the weather strip would probably be a great solution.

 

Maybe redo it and add some silicone (good marine grade) into the hole before putting in the thumb screws.

 

Thank you guys all for the suggestions, you’re all life savers!

On a somewhat related note, has anyone experienced the third brake light leak? If so, where does the water enter the cab?

I’m going to have to start looking at that as a possible culprit if this fix doesn’t work.

 

This. Ive used the gorrilla glue brand for some things with my homes sump pump and it works brilliantly.

 

Yes, Toyota just sent out a warranty repair mailer for that issue. However, the years affected are 16-19. Very surprising you're having that problem on a '21

 

I’ve checked the VIN already and it says I don’t have any recalls. At this point I’m still fairly positive it’s coming in through one of the spots where the roof rack used to be mounted.

I’m just curious if the water entry points for the 3rd brake light leak match up to what I’m experiencing.

 

Mission accomplished. Thank you everyone for your help and suggestions. Now I just have to wait for rain and see if it works.

Pics below are in order from start to finish. These are also good for anyone wondering what’s actually under the weather stripping on the roof.

My half assed original attempt at silicon:



Stripped out all the silicon down to the bare holes. Cleaned them out with Q-tips and dried them with a hair dryer.


New commercial-grade silicon applied directly into the holes:



Gorilla-Glue brand weatherproof tape on top of silicon to seal it all in:

 

Didn't realize there was such a large opening around the holes. Might be too late, but I'd apply that tape over that whole rectangular area.

 

yeah, why didn't you put one large piece over the whole area?

Clean up the old silicone. It's really bothering me...

 

That’s a really good point. I actually considered doing that, but my thought process was that the lip between the painted and unpainted part could allow some water to get under the tape.

I would hope that wouldn’t be an issue since the silicon is fully sealing the hole underneath but I figure better safe than sorry.