$2500 roof repair!

1Stewj · **Posted:** Mon Oct 20, 2014 2:19 pm

Everyone who has a KK should remove their racks and check for cracks in the paint along the entire rail "gutter" and near the Factory rack mounting studs. ANY upward pressure on the rack, will put separating pressure between the roof panel and the outer side panel. The roof metal is spot welded and caulked not bonded to the outer panel. Over time the cracks WILL appear and let water run into the vehicle. I was told that because I was over the 3yr36k period, it won't be covered. Understood, but all of the rust and cracks were covered by glued on trim or factory rack feet.

I repaired one on the passengers side and it stopped the leak into the rear gate area. The undetected drivers side rear rack mounting point leaked for an extended time unnoticed. Only finding standing water in the front and back drivers side did I realize there might be another leak. Low and behold (after removing my ENTIRE interior did I find out how destructive this can be. Rust on the inner floor pan, wiring soaking in water, seat mounting bolts rusting, saturated carpet padding..... And a BF'ing rust hole in my roof. $2k+ for repair of a NON SKYSLIDER roof. I didn't want a SKYSLIDER because of the potential for any leaks.

This is a big issue for KK owners. I love my Jeep, but how Jeep handles this might change my mind. Anyone have any experience with this drastic of an issue?

JeepMorrison · **Joined:** Thu Jul 16, 2009 11:34 am **Posts:** 1236

Save 2500 bucks and cut the roof off.

Sent with the power of children's screams!!!

lfhoward · **Posted:** Mon Oct 20, 2014 3:05 pm

Yes, had these issues too. http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=104&t=63948

Went for a less expensive fix:

No more leaks.

wildemt · **Posted:** Mon Oct 20, 2014 3:48 pm

Oiy, that settles it. Bikes are going on a hitch carrier.

1Stewj · **Posted:** Tue Oct 21, 2014 4:16 pm

I did that repair also. Point being, cracks form underneath factory installed trim and rack feet. Most won't remove and or notice a leak during the warranty period. Working on contacting Jeep to fix.

KKnut · **Posted:** Wed Oct 22, 2014 7:35 am

Thanks for bringing this to my attention, will be checking this very soon.

CorporeSano · **Joined:** Sun Oct 19, 2014 2:36 pm **Posts:** 75

Any instructions on removing the factory roof rack? I observed that the factory rack on my 2012 Liberty Sport seems to be more cosmetic that functional. I can't attach anything to it, because its solid plastic back to front..

lfhoward · **Posted:** Wed Oct 22, 2014 2:00 pm

CorporeSano wrote:

Any instructions on removing the factory roof rack? I observed that the factory rack on my 2012 Liberty Sport seems to be more cosmetic that functional. I can't attach anything to it, because its solid plastic back to front..

Instructions are here: http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?p=843689#p843689

CorporeSano · **Joined:** Sun Oct 19, 2014 2:36 pm **Posts:** 75

Great I should of read that in detail the first time.. So when the factory roof rails come off... If I buy a basket or real roof rack options, do the new replacements come with the black trim to cover up the white seams in the roof that are under the factory roof rails ?

Do the factory roof rails have any purpose besides cosmetic ?

Bmxer524 · **Posted:** Wed Oct 22, 2014 6:33 pm

CorporeSano wrote:

Great I should of read that in detail the first time.. So when the factory roof rails come off... If I buy a basket or real roof rack options, do the new replacements come with the black trim to cover up the white seams in the roof that are under the factory roof rails ?

Do the factory roof rails have any purpose besides cosmetic ?

They have 2 roof rails. You have the kind that both you and I have, which are solid and meant for looks. I generally see them on all sky slider models. And they have a functional kind. They're lifted a bit.

What seams are you mentioning? If you pull them off you'll have some tape to clean up. After that all that's left is the channel they sit in and the studs they attach to. You'll need to buy new side rails. Either factory(pretty sure they're plastic as well), or aftermarket. AtTheHelm makes metal side rails. I think they're reasonably priced too. I'm hoping to be buying a set in the next few months or so.

lfhoward · **Posted:** Wed Oct 22, 2014 7:12 pm

CorporeSano wrote:

Great I should of read that in detail the first time.. So when the factory roof rails come off... If I buy a basket or real roof rack options, do the new replacements come with the black trim to cover up the white seams in the roof that are under the factory roof rails ?

Do the factory roof rails have any purpose besides cosmetic ?

Sorry, I should have read your post better. I didn't realize you had the cosmetic black strips. They can be pulled up and off too. As Bmxer said, you'll have some 3M double sided tape to get off with those afterwards.

You can get the Mopar side rails and Mopar crossbars or make your own crossbars like this: http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=59&t=72548 or if you go with a steel rack from Rock Lizard or AtTheHelm, they bolt directly to the roof studs so no need for factory rails. E.g., http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=34&t=79290

CorporeSano · **Joined:** Sun Oct 19, 2014 2:36 pm **Posts:** 75

Jeep denied my claim for a repair for this issue. I went through the dealer, customer service, digital imaging and some escalated customer service that ended in a big no. They tried to negotiate by extending my power train warranty.
I have a 2012 KK with 45k

Here's my fix.

OP can over tightening the roof rail nuts cause "Upward Pressure"?

lfhoward · **Posted:** Tue Feb 17, 2015 9:19 pm

Looks just like my roof. :wink:

Got to picture a blue KK with black sealer instead of white.
I think the cracks develop from use of the roof rack (which I use a lot) or just from vibration over time. Some folks found cracks up there who don't even have side bars or cross rails at all.

I was thinking of picking up another tube of the 3M sealer soon. I noticed today that some of the sheet metal welds above my tail light are coming apart due to vibrations and stresses from my CB antenna. It looks like much the same issue, although in a different location. Water and salt intrusion have started rusting the area and I'd like to completely clean and seal it to stop the degradation.

PALiftedKK · **Posted:** Wed Feb 18, 2015 9:47 am

Im planning on doing this this summer. Any one want to help me take the 100lb solar panel down. again...

$2500 roof repair!

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