Re: Installing OEM roof rack. Help
Congrats on the new rack - I think the worst element of the FJ is the stock rack, but won't get into that. I installed a Baja flat rack and am loving it. However, had some serious headaches when removing and installing because of the bolt-clips below the roof and under the headliner.
Basically, the Baja rack provided only bolts and stanchions, but no spacers, fiber washers, or anything to cover the access to the bolt holes through the roof. I installed mine with the original FJ clips found under the original rack stanchions, though there is no instruction to do so. Simply adding silicone sealant to the thread holes won't waterproof the system as there are gaps where water can get in through the roof. I ended up gunking up the works with silicone and hoping for the best. So far, no problem, but I have a very low confidence that this fix will last. I'm just going to keep an eye no things to see if there are any leaks. I'm more concerned that leaks will find their way past the roof into the body, without being evident on the headliner. Hopefully that won't happen.
I purchased my 2012 used and the previous owner did sound proofing/reducing under the headliner and elsewhere. This resulted in gumming up the threads on the clips, ultimately causing me to have to remove the headliner after the metal clip slipped and made it impossible to take the bolts out. I also stripped several of the factory bolts in the process, also necessitating the removal headliner to access the bolt clips. Several bolts had to be drilled out to remove them. I don't think an original installation would have had as much of a problem. It looked to me that spray paint had made it onto some of the bolts, thus creating an unusual problem.
So glad to be rid of the original FJ rack. Now can walk on the roof if I need to, sleep up there, and have a thousand attachment points. Expensive, but worth it.