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Discussion Starter #1
Issue #1
I have tried the search multiple ways for a roof rack that is rattling.... I have tried to tighten the star bolts but they are all tight... there is just space between the crossbars and the mounts they use that causes a annoying rattle when driving.

Issue #2
a clunk in the suspension when turning... I have a Daystar spacer 2 3/4" liftkit that is clunking while I turn the wheels (pop)... I have tried to contact Daystar but they dont seem to return messages on thier website... go figure. Should I just lube em up?

Any help would be great!

BP
 

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For issue one: There are a couple of different posts I found about the rattle.
http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/1959-roof-rack-noise.html#post53905

http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/3939-roof-rack-rattle-speed.html

I've installed washers after I moved my bars to fit my rack. It seems to help, so does the weight of the rack its self sitting on it.:) The Torx screws bottom out on the rail and not on the plastic ends. So the washers make the screws lock down on the plastic and the bar. This pretty much stop the noise.:)
there is a bit of play between the metal crossbar & plastic end fitting. Instead of a washer, I used a small square of rubber-about 1.5" wide- a little chunk of that pond liner material in this case. Stopped the wobble.
Also just found http://www.fjcruiserforums.com/forums/general-discussion/4584-toyota-announces-roof-rack-cross-bars-fix.html which includes this info:

The kit Toyota has come up with to fix the rattle noise is PT278-35070-WK.

The repair is covered under your factory warranty and can be done at any Toyota dealer.

Per Technical Service Bulletin AX006-06.

If your dealer does not know of this fix just give them the TSB# AX006-06.

Matt
Hopefully that will help!
 

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i have know idea because i have a rattle that the dealer cant find its been making it for 10k. But the threads about the roof rack should fix your problem.
 

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Most likely you dealer won't fix your roof rack because you "altered" your suspension and voided the warranty. :stickpoke:

Don't forget to take a lawyer with you to the dealership. :rawr:
 

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That service bulletin is quite old. Do you think that they would have the issue corrected with newer models? Or is this an issue that we should all continue to monitor?

Speaking of service bulletins: Does anyone know if there's an online source to view TSB's for the FJ?

Edit: Just noticed that the OP's forum join date is May 2006, so probably has a model that is affected...
 
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