Member Since: 07 May 2017
Location: Dundee
Posts: 58
Roof rail antics!
So I have a d4 GS. It didn't come with roof rails, so bought a set from a breakers. Attempted to remove the plastic grommets, but they were stuck fast. Even with wd40 there was no movement. YouTube vid lied!!
Anyway, this is drilled out. Long story short is that plastic remained after i thought was removed. This caused the bolt to snap inside, then drilling this out has also failed. So, my question is: How easy is it to remove the nut from the roof? Do i just drill out the welds around it?4x4 Phase:
D4 - GS - Tints - More mods to follow.
Honda CRV 2.2 ctdi - owned 5 Years - Sold
Nissan X-trail SVE 2.2d - Written off after 1 year
Toy - Yamaha xjr 1200
9th Jun 2018 1:53 pm
deanslandy
Member Since: 17 Jan 2015
Location: nuneaton
Posts: 646
Hi,
I wouldn't remove the nut from the roof I would try and either clean out the existing thread and re tap or helicoil insert
There are many vids on tinterwab on how to helicoil
Belts, oil pump casing and water pump by Flack
Transmission flush by Geoff
9th Jun 2018 2:23 pm
Narpy
Member Since: 18 Jul 2011
Location: Stockport
Posts: 7830
Why were you using WD40, you dig the plastic plugs out with a small screwdriver and the jobs done?Mods:
Front Fogs + Halos
FBH Remote Control
The 1st Ever RRS Modded Grill
Garmin Nuvi + D4 Surround + Reversing Camera.
D4 Steering Wheel.
Rear Boot Spoiler.
Twin Brake Lights.
Wing Mirror Indicator Repeaters.
Long Roof Rails
Make your own Narpy grill thread
I'm not scared, I'm outta here.
9th Jun 2018 2:57 pm
dstevec
Member Since: 07 May 2017
Location: Dundee
Posts: 58
The plugs were jammed tight. Tried to lube them with wd, but that didn't work. Finally worked out that they unscrew very easily, so youtube video was steering me in the wrong direction.
I'll have a look at helicoil. Cheers 4x4 Phase:
D4 - GS - Tints - More mods to follow.
Honda CRV 2.2 ctdi - owned 5 Years - Sold
Nissan X-trail SVE 2.2d - Written off after 1 year
Toy - Yamaha xjr 1200
9th Jun 2018 3:29 pm
Grease Monkey
Member Since: 24 May 2009
Location: Essex
Posts: 134
Re: Roof rail antics!
dstevec wrote:
So I have a d4 GS. It didn't come with roof rails, so bought a set from a breakers. Attempted to remove the plastic grommets, but they were stuck fast. Even with wd40 there was no movement. YouTube vid lied!!
Anyway, this is drilled out. Long story short is that plastic remained after i thought was removed. This caused the bolt to snap inside, then drilling this out has also failed. So, my question is: How easy is it to remove the nut from the roof? Do i just drill out the welds around it?
The nut isn't welded, you need to dig out the sealant around the hex nut remove it and replace with a new one then reseal.
Part No. AYR500061
Hope that helps,
GM2009 D4 Zermatt Silver SE (Pre-Production) - Current
2014 FL2 Santorini Black HSE - Current
2009 FL2 Zermatt Silver XS - Gone
2005 D3 Zambezi Silver S (ex Bigdave) - Gone
2005 D3 Zambezi Silver SE - Gone
9th Jun 2018 8:45 pm
dstevec
Member Since: 07 May 2017
Location: Dundee
Posts: 58
This is the best news I've had in ages! Thanks for this! 4x4 Phase:
D4 - GS - Tints - More mods to follow.
Honda CRV 2.2 ctdi - owned 5 Years - Sold
Nissan X-trail SVE 2.2d - Written off after 1 year
Toy - Yamaha xjr 1200
10th Jun 2018 12:18 am
Grease Monkey
Member Since: 24 May 2009
Location: Essex
Posts: 134
No probs
A few of us have had similar issues
Good luck with fix
GM2009 D4 Zermatt Silver SE (Pre-Production) - Current
2014 FL2 Santorini Black HSE - Current
2009 FL2 Zermatt Silver XS - Gone
2005 D3 Zambezi Silver S (ex Bigdave) - Gone
2005 D3 Zambezi Silver SE - Gone
10th Jun 2018 8:37 pm
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
Anyone know the inner thread width please?
Thinking of just bolting straight through and saving moneyDisco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
11th Feb 2022 12:23 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15213
It's an M6 bolt [I believe with a thread pitch of 1.0]
For bolting down roof rails then its a max shank length of 22mm.
If bolting down direct [eg roof rack bracket] then it's a max shank length of 15mm .
edited to add: if the nut hasn't previously had a bolt threaded in it, then you'll need to clean it out, either with a tap& die set or a cut bolt.
Last edited by ronp on 11th Feb 2022 1:07 pm. Edited 1 time in total
11th Feb 2022 1:03 pm
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
The width I’m after sorry. Not the top smaller bolt but the inmer thread. It’s either 8 or 10Disco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
11th Feb 2022 1:05 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15213
Don't know if were talking about the same thing here
But my roof bolts are M6 [which by definition have a 6mm diameter thread and which screws into a 6mm inner thread].
11th Feb 2022 1:22 pm
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
Just took one out it’s m10
I’m in about the adapter plug thing that sits in the roof for the m6 to bolt rail on toDisco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
11th Feb 2022 1:39 pm
Robbie
Member Since: 05 Feb 2006
Location: ¯\_(ツ)_/¯
Posts: 17932
cmb2020 wrote:
Anyone know the inner thread width please?
Thinking of just bolting straight through and saving money
Bolting through is a good idea when carrying a proper load. The little M6 screws don't have much shear strength - hence the low published load rating for the roof system.
Land Rover - Turning Drivers into Mechanics Since 1948
Member Since: 02 Jun 2021
Location: Seattle
Posts: 183
Robbie,
When you say bolt directly through, do you mean:
1) Remove the existing stud (below) and use it’s nut inside the roof to retain a larger bolt, which connects the roof rail
Or
2) Drill new holes along the roof line and add new through bolts? I presume this would require pulling headliner at the edges and using some washers to spread the load.
I assume it’s #1, but I know I’ve seen people do #2. Option #1 seems pretty straight forward, and actually something I may do when I mount my roof rack.2008 LR3 HSE, 4.4L V8
11th Feb 2022 2:11 pm
robpenrose
Member Since: 12 Jan 2016
Location: Surrey / SW London
Posts: 2136
Robbie wrote:
cmb2020 wrote:
Anyone know the inner thread width please?
Thinking of just bolting straight through and saving money
Bolting through is a good idea when carrying a proper load. The little M6 screws don't have much shear strength - hence the low published load rating for the roof system.
Haven't seen you post much these days Robbie. Hope all is well
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