TRD Pro (2019+) Roof Rack Install – 5th Gen 4Runner

TRD Pro (2019+) Roof Rack Swap and Installation Guide – Parts List and Overview For the 5th Gen 4Runner

Back in 2019, Toyota paid tribute to the FJ Cruiser by incorporating its roof rack onto the TRD Pro 4Runner. The basket style roof rack is definitely a departure from the rails and crossbars roof rack from past 4Runnners.

There is some discussion on how this rack looks; some people don’t like it and some do. I fall under the latter category, and when I came across one in my area, I jumped on the opportunity.

A used TRD Pro Roof Rack can usually be found for sale on Facebook Marketplace/Groups, Offer Up, Vilmont Market, etc. You can also buy a new Pro Rack (PT278-89190) from the dealership, however, this will be the more expensive option.

Buying a Used Roof Rack

When buying a used TRD Pro Roof Rack, I highly recommend getting a hardware kit (PT278-35130-HW) since the foam and fiber washers will most likely need to be replaced. My recommendation is from the FJ roof rack. It is the same hardware as the TRD Pro Hardware Kit (PT278-89190-HW) at a fraction of the cost (~$20 vs. ~$102), plus it comes with extra screws and washers. Also make sure you are getting 4 roof Brackets (63185-42020), if not you’ll have to order them from the dealer.

What You’ll Need For Installation

Source the Parts: 

• TRD Pro Roof Rack Kit (PT278-89190): Check Price
• Roof Rack Hardware Kit (PT278-35130-HW): Check Price
• Roof Rack Bracket (63185-42020): Check Price

Buy the Rack Kit:

• OEM TOYOTA roof rack: Check Price
• OEM Style roof rack: Check Price

Tools & Materials:

• Torx Bit Set
  • T40 Torx Driver
  • T25 Torx Driver
• Socket Set
  • 3-12″ extensions
• Wrench Set
• Torque wrench (Needs to torque to 18.0 Nm +/- 3 Nm or 13 lbf-ft)
• Impact Driver (optional)
• Trim removal tool(s)
• Large Towel
• Shop Towels
• Multi-Purpose Cleaner
• Isopropyl Alcohol (not pictured)

Step 1. Remove Stock Roof Rack & Clean Roof

Start by removing the 4 roof rail plastic caps. Once the caps have been removed, use a 12mm socket to remove the 8 screws holding the roof rails to the roof. Remove the roof rails and clean the area where the rail base previously contacted the roof.

Step 2. Install Brackets

Install 4 brackets (63185-42020) at each of the roof mounting points. The brackets should be positioned so that the tabs are facing towards the doors.

Step 3. Prep Roof Rack Install

Before lifting the roof rack on top of the roof of the 4Runner, I recommend taking 3 of the crossbars off to reduce weight. Keep one crossbar attached towards the front of the roof rack to maintain rigidity when the roof rack is lifted over the vehicle.

Step 5. Apply Foam Washers

Clean the spools (metallic bushing) with some isopropyl alcohol.

Peel off the adhesive backing on the foam washers and adhere the foam washers onto the bottom surface of the spools. You’ll have to do this for each of the 8 spools. Take the time to do this right since the foam washer will act as a water barrier once it is sandwiched between the spools and brackets.

Step 6. Position Roof Rack On Top Of 4Runner

With the help of a friend, lift the rack over the vehicle. This can be done by a single person but I recommend putting a towel down on the other side to prevent damaging the roof. Another option is to separate the left and right half of the rack by completely removing 2 M5 screws from the connector.

Next, loosen the 2 thumb screws located on the crossbar (see photo on the left above).

Loosen the 4 M5 (T25) screws on the connector. Then, position the rack so that the holes align between the roof rack and the roof. Make sure that the foam washers are not blocking the hole openings.

Step 7. Install Roof Rack

Install the M8 (T40) screws and fiber washers by hand in all 8 locations (front and rear end support). This is only to start the thread, do not fully tighten at this point.

Note: Do not forget the fiber washers; they seal the gaps between the spools and screws to prevent water from getting in.

Make sure the front and rear end support sits on the roof and follows the roof’s contour.

Begin tightening the 4 rear end support screws first then move onto the 4 front end support screws. Check and verify that all end supports are properly seated onto the roof.

Torque the screws to 13 lb-ft (18.0 Nm +/- 3Nm). Starting again with the 4 rear end support screws first. Alternate between the screws when torquing to draw down the supports evenly.

Tighten the 4 M5 (T25) screws on the connector, torque to 35 lb-in (4 Nm) or just hand tight.

Step 8. Install Crossbars

Note the crossbars are orientation specific. All crossbars will have to be installed with the arrow facing “FORWARD” and the thumbwheel knobs facing up.

Double-check and make sure the lower clamps are on the correct side (LH vs. RH). If the clamps are on the wrong side, they will not be able to be installed. Separate the lower clamps along with the thumbwheel knobs to their respected side and place them on top of the roof, they will have to be separated in order for the crossbars to fit over the rails.

Step 9. Reposition Crossbars To Finish Up!

The last step is to remove the lower clamps from the crossbars and then position the crossbars between the vertical rail sections.

After that, you’ll need to loosen the inner thumbwheel knobs to adjust the width of the crossbars as they are positioned in place. Lastly, attach the lower clamps with the thumbwheel knobs on both sides, and then center the crossbars and tighten the inner thumbwheel knobs.

Final Thoughts

The install on the TRD Pro Rack is pretty straightforward and it took me about an hour and a half to do.

When installing this rack, one of the main concerns I had was a leaking roof. I contemplated reusing the old hardware, but after looking it over, I decided for peace of mind. Replacing all the hardware was the way to go, and given the low cost of the kit, it was a no-brainer. I can happily say after multiple Costco car washes I have zero leaks!

I’ve used this rack a few times for hauling, camping, and climbing gear and it has worked out great for me and definitely freed up the much-needed trunk space!

The TRD Pro Roof Rack is a good looking rack in my opinion and if one comes across you at a great price, I would highly recommend picking it up!

Updates

After having the rack installed for a while I’ve decided to mount my Pelican Storm case to the top for some extra weatherproof storage. I’ve seen some rail bolt combo similar to how roof top tents are mounted but didn’t like the look plus taking it on and off seemed like a pain. I wanted something more stream lined and can be removed with relative ease.

Here is what I’ve came up with:

1/4-20 Rivet Nuts installed in crossbars.

Thumb screws to hold the Pelican case to the crossbars.

All set for more gear storage!