Roof Rack Blanking Plug Removal

[Stuart551]

Ok, the genuine rails couldn't be more different to the aftermarket ones, the ends are a different shape and the bars are about 3 times the diameter. Also crossbars, I've been looking myself, and again you probably need genuine ones ex-Citroen or Peugeot for the proper size as most aftermarket ones will not fit the thick PSA rails.

My bolts were all the same size / length, front and back. They were originals by part number ordered from a Citroen supplier and went in no problem at all, on the citroen parts diagram it is one bolt P/N on all roof mounting hole bolts. If they were different, there would be 2 part numbers.

I've attached a pic of the ends of my proper ones (pic1), that shows the difference pretty clearly if you compare it to aftermarket ones. (pics 2 & 3)

The aftermarket ones which absolutely flood the internet & ebay, are cheap bits of bent aluminium tubing, the originals are thick rails of solid alloy bar, but are expensive new (£320+ a set) and used ones are rare but they do come up. If you only want them for looks, then the aftermarket ones would be ok if they are a good fit. The real ones are rated to 75KG loading, the aftermarket ones rarely go over 32KG.

Hey dude hope you don’t mind me bumping such an old thread. You recommended https://peugeotcitroendsparts.com/peugeo...ew-9035s1/

For fitting the roof rack. I’ve just ordered them but I’m just wondering if you could help me with the type of socket/tool I would need to fit them. I tried to find it myself but the part number doesn’t give very much information. The only picture looked like a male torx so I would need the female equivalent but can’t really find anything. Thanks for any help bud.

[Chilly Slang]

The 2013 Mspace XTR that I just purchased has aero looking roof bars that run front to back. They have large plastic covers at each end. In between, on the roof I can see a mounting plate. I am very grateful for the tip about the tapered bolts since it probably saved me from damaging something trying to fit M8 bolts. How do the plastic covers come off if I want to remove the existing roof rails to put on something more robust and useful?

[AdamOSLMFB]

I'm having the same sort of problem only the plastic plugs have broken off leaving me with the blanking plug stuck in the holes and seemingly no way to get them out, I'm at my wits end.

[Sol]

Ok, the genuine rails couldn't be more different to the aftermarket ones, the ends are a different shape and the bars are about 3 times the diameter. Also crossbars, I've been looking myself, and again you probably need genuine ones ex-Citroen or Peugeot for the proper size as most aftermarket ones will not fit the thick PSA rails.

My bolts were all the same size / length, front and back. They were originals by part number ordered from a Citroen supplier and went in no problem at all, on the citroen parts diagram it is one bolt P/N on all roof mounting hole bolts. If they were different, there would be 2 part numbers.

I've attached a pic of the ends of my proper ones (pic1), that shows the difference pretty clearly if you compare it to aftermarket ones. (pics 2 & 3)

The aftermarket ones which absolutely flood the internet & ebay, are cheap bits of bent aluminium tubing, the originals are thick rails of solid alloy bar, but are expensive new (£320+ a set) and used ones are rare but they do come up. If you only want them for looks, then the aftermarket ones would be ok if they are a good fit. The real ones are rated to 75KG loading, the aftermarket ones rarely go over 32KG.

Hey dude hope you don’t mind me bumping such an old thread. You recommended https://peugeotcitroendsparts.com/peugeo...ew-9035s1/

For fitting the roof rack. I’ve just ordered them but I’m just wondering if you could help me with the type of socket/tool I would need to fit them. I tried to find it myself but the part number doesn’t give very much information. The only picture looked like a male torx so I would need the female equivalent but can’t really find anything. Thanks for any help bud.

Sorry for the late reply, not on here much lately as I've got other things going on. The tool is a Torx male, as the bolts have a female head (albeit a big mushroom shape like a button with the sunken Torx in the centre) - from memory it was a T10 or something, fairly beefy but not huge. You can get individual bits in Halfords to fit them. I used a loose Torx key to spin the bolts in then a 1/2" Torx socket bit to tighten them.

[Sol]

The 2013 Mspace XTR that I just purchased has aero looking roof bars that run front to back. They have large plastic covers at each end. In between, on the roof I can see a mounting plate. I am very grateful for the tip about the tapered bolts since it probably saved me from damaging something trying to fit M8 bolts. How do the plastic covers come off if I want to remove the existing roof rails to put on something more robust and useful?

Not sure if you have OEM ones, but if you do, then squeeze the large end covers in from the sides (across the way) and pull upwards, they just unclip. Under the covers is a single bolt at each end.

[Sol]

I'm having the same sort of problem only the plastic plugs have broken off leaving me with the blanking plug stuck in the holes and seemingly no way to get them out, I'm at my wits end.

The plugs are the fir-tree kind, and yeah the heads often pull off leaving the shank in the hole. You can try needle nose pliers, or try to screw a thin woodscrew into the centre of the old plug shank carefully with a hand driver and once it has a bite, pliers should pull the remains out of the hole. If need be, drill a fine hole about 3mm drill size into the end of the plastic plug shank about half way down (all the way is ok too, just don't press hard - its only soft plastic so will drill easily), then twist an M4 self tapping screw or wood screw into it as above and it should get hold of it. The bolt threads and steel plates are pretty robust plus the insert in the roof is thick at the bottom so you won't go through that with the drill or screw.

Alternatively once a pilot hole is in the end of the plastic plug, run a 6mm drill down the center and it would eat most of the plug, stop when it hits the bottom of the steel insert. You would be able to pick the small bits left out, with needle nose pliers.

[AdamOSLMFB]

I'm having the same sort of problem only the plastic plugs have broken off leaving me with the blanking plug stuck in the holes and seemingly no way to get them out, I'm at my wits end.

The plugs are the fir-tree kind, and yeah the heads often pull off leaving the shank in the hole. You can try needle nose pliers, or try to screw a thin woodscrew into the centre of the old plug shank carefully with a hand driver and once it has a bite, pliers should pull the remains out of the hole. If need be, drill a fine hole about 3mm drill size into the end of the plastic plug shank about half way down (all the way is ok too, just don't press hard - its only soft plastic so will drill easily), then twist an M4 self tapping screw or wood screw into it as above and it should get hold of it. The bolt threads and steel plates are pretty robust plus the insert in the roof is thick at the bottom so you won't go through that with the drill or screw.

Alternatively once a pilot hole is in the end of the plastic plug, run a 6mm drill down the center and it would eat most of the plug, stop when it hits the bottom of the steel insert. You would be able to pick the small bits left out, with needle nose pliers.

This worked a treat! Was able to get two out with NN pliers and used the drill to get the rest out, only to find that the bolt holes are filled with rust, I have a tap but really only want to use it as a last resort... I'm thinking of getting 9mm gun cleaning brass brushes, put them on the drill and try to clean them out, unless there is an easier way to sort or replace them?

[Sol]

I had the same experience. I ran a tap down with a bit of oil just to clean the threads. It binds near the end but I just back off. The proper bolts went in a turn at a time, screwing back half a turn, then back in 2 turns, back and forth till they were seated.

Fill the holes with WD40 or lusol etc and leave for a few hours, then the bolt or tap should work. Just be canny, go slow. Back and forth till the bolts go right down then copper slip or grease the bolts and fire the rails on.

[Wightlingo]

Bit of an old thread revival but... I wanted to fit an awning rail to the XTR so removed the roof rails, nobody told me about tapered bolts so I bought M8 stainless ones ,once they were cut to size they fitted with no problems at all . I made up some aluminimun brackets the same length as the plates on the roof and will fix a board to them, I may try the metal clips that market stalls use for a quick release system.