answered: hardware size m8x35mm Allen head bolts.

drill out plastic. Re-tap threads. Install with new bolts.

Hi All,

trying to install the back crossbars on my 04. The Allen head bolts where they go seem to be plastic and won’t budge. A 4mm Allen wrench is too small, and 4.5 is too big…

What do these bolts look like removed? Is there a nut locked in below? Can I drill them out and retap safely without going through the roof?

Pics below for reference

 

Hi Michael,
those tubes are pretty thin, I remember from when I was putting them on, but I don’t remember what was the Allen screw’s holding , the bracket that has bolt going trough roof seemed welded to tube unless I am mistaking someone correct me,
truck looks awesome by the way.

 

Hey Andre,

Nice to see you post! I can't remember if you're the one who installed the 04 rails or the owner before you, but if it was you, do you remember if you installed those Allen head bolts or if those were always on the truck?

I'm thinking I'm going to drill them out and replace them with either a riv-nut or try to re-tap whatever is holding the current bolts in.

 

Those are held in by bolts on the inside under the headliner - I think

 

Where did you get the cross bars? I'm looking for some as well.

 

Yes I put the roof rails, when rails are off the roof if you look inside really don’t see anything , so I am not sure if Allen screw’s are holding the actual bracket that has the big bolt that goes trough the roof ,
but if bracket is not welded to tubes & Allen screw is holding bracket then you don’t want to take Allen screw off,
i don’t know if it make sense !

 

Solved by disco_stu on Instagram. M8 bolts

 

I picked these up from will tillery (roverguy.com) for a screaming deal of $130 shipped. People sell them for 250-400 often times. They’re OEM so your only option is used on eBay, forums, Facebook, or parts sellers