2004-2006 Expedition roof rack fix

[bmerr98]

If you have a 2004-2006 Expedition with the raised side rail type roof rack, but are missing the cross rails, I found a much cheaper way to replace them than spending around $100 for a new pair off EBay.

There are some Chevy Blazers and Montana minivans with similar raised side rails. The cross rails can be trimmed to fit the Expedition side rail slots. The length of the cross rails is 38" from side rail to side rail. I found some at my local Pick-a-Part today. Paid $12.95 for two cross rails including tax and the $2 fee.to enter the yard.

As I said, some trimming is required. The space in the Expedition side rail is about .53" and the piece on the cross rails is almost .75". A Dremel tool works well for trimming the plastic. I figured it out, I'm sure anyone else can.

 

[MastuhWaffles]

Yeah, my mom's 05 expedition has one, but sadly has never been used... But more problems are with the engine.

 

[bmerr98]

I'll try to post a couple of pics in the next day or so. Home computer is down and I can't figure out how to get it done from my phone.

 

[bmerr98]

Ok, here are some pics of the roof rack fix. I apologize for not having more info on what year Blazers/Montana minivan to scavenge from. Next time I get by the bone yard I'll see what it was and update this post. I did have to remove and disassemble the entire roof rack from the donor vehicle. 8 T-25 torx screws if I remember the size right.

This is the style of raised side rail I was working with.
View attachment 11750
This is the inside measurement of the C channel
View attachment 11751
This is the trimmed piece that slides into the C channel. Didn't think to get a pre-trimmed pic.
View attachment 11752
This metal piece will also have to be trimmed. It clamps to the inside of the C channel.
View attachment 11753
Installed
View attachment 11754
View attachment 11755
Couldn't get the straight on view to load, but here's my thrift shop box mounted. Snagged it for $25!
View attachment 11756

Hope it helps. My total cost was $40.27 including tax and the $2 lot fee to get into the bone yard. $12.95 for the rails, $27.32 for the box. With a new set of Ford rails going for about $100 on eBay and the box listing for $385 on GMAccessorieszone.com, I figure I did ok

 

[bmerr98]

Update: The donor vehicle was a 2000 Blazer. Another potential donor was a 1998 Pontiac Montana minivan. Other years may also work.

 

[MastuhWaffles]

There should be a tech article section for stuff like this!