D4 Roof Rail Fixings failure

[David Hannett]

Looking for advice please - MY11 D4 - Roof Rail fixings are failing fairly frequently after many years of no issues - are there any tips or tricks when replacing a failed fixing please? The fixings are a two-part piece (AYR500061) and appears some care needs to be taken not to over tighten the hollow lower piece before inserting the inner upper piece. Can’t find any instructions in the workshop manual.
First occurrence was after extended off-road (Cape York, Gulf Country, Finke River) and carrying fair load on roof (half-width basket, spare wheel, spare tyre, 4x MaxTrax).
Any advice and suggestions most welcome thank you.

[scarry]

I used the Rhino tracks on mine,for almost ten years,overloaded on some trips,a lot of corrugated roads,etc,no issues.

FItted with heavy duty bars and the Rhino legs.

The system works well

Maybe you could look at them?

Hot tip,if you put a roof bar on the lower roof section,the noise will drive you crazy.
I just used two bars on the upper section,no noise at all.
These two were used mainly for RTT and awning.

Good luck with it all.