Welcome to Toyota nation.

Geometrically, one side of the vehicle is off compared to the other side.

How obvious is the offset with caps installed?

 

Thanks for the welcome!

There is a small amount of overhang on the front of the car, where the trim meets the windshield. Would not have noticed this unless I was putting together that the rack landing pads didn't fit. Front and rear landing pads are not the same, but it is symmetric left and right (both trim rail appear to be installed just a little too far forward).

 

For 2015 Highlander XLE, my roof rail trim (silver, runs parallel to the vehicle) is just 2-3mm forward. When removing the trim cover plates to expose the roof screw holes to install a roof rack (mine happens to be a Yakima rack but would apply to any rack), the roof screw holes are not in the center of the rail trim opening--they are off by just enough that the roof rack towers don't line up with the screw hole. All 4 locations (driver and passenger side, front and back) affected.

Anyone else have this problem?

Took it to a dealership, they agreed, both sides are just barely off. They suggest remove trim and reinstall ($1700). Obviously installed incorrectly from manufacturer, Toyota Brand Engagement Center says they'll not cover it because warranty is up, and they have no other cases of this. Looking for those other cases, find me if you're out there, wandering rackless and afraid.

Otherwise solutions welcome (other than the obvious one of forking over $1700).

Thanks!
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Had the same problem same ride except limited trim and it from factory like that and they wanted to charge me a new seat event though still under warranty for everything this is my last year will expire. Cost was $1500

Problem I had was after long trips and vibration screws came loose and it started hitting top of my roof I took it off while on expressway could easily flown off almost till I stopped.

have yet to put it back on or another brand but soon need to do something I miss my roof rack

 

Frustrating. Yeah, seems like they aren't into endorsing they did it wrong but not sure how else it could end up off by a few mm, evenly on both sides. Will let you know if I get anywhere with Toyota BEC who is reviewing the case but I'm skeptical.

Had the same problem same ride except limited trim and it from factory like that and they wanted to charge me a new seat event though still under warranty for everything this is my last year will expire. Cost was $1500

Problem I had was after long trips and vibration screws came loose and it started hitting top of my roof I took it off while on expressway could easily flown off almost till I stopped.

have yet to put it back on or another brand but soon need to do something I miss my roof rack

 

Since they aren’t connected to each other, the bracket inside the roof is fatigued. A body shop should be able to install a new bracket and possibly fix the issue.

Are you the sole owner op?

 

OK, interesting. Yes sole owner/operator since I bought it (new).

 

During assembly welding, the roof bracket could move during the welding if it’s not in the welding jig at the right spot.

This happens more often than not, but when it’s assembled, the bracket would be aligned properly. The threads could be at an angle. This would push the roof rail to one side.

Something to keep in mind.

 

So interestingly, I discussed the case with Toyota's Brand Engagement Center and they initially denied the claim. But after I made enough of a fuss (and threatened a small claims suit--which I'm sure I'd lose frankly), they reviewed the case and agreed to cover the cost of trim replacement. I'm not sure what prompted them to pay for it (aside from doing what I view is the right thing) but impressed with the brand that they did this.

 

That’s good to hear that they are putting their best foot forward.

Hoping that it will fix the issue and won’t be a problem in the future.

 

Final wrap up here: After BEC agreed to replace the trim, the dealership did so, only to then say they think the problem was actually caused by trim misplacement after I had the windshield replaced (which I did about 3 years ago). So turns out my bad after all (although not sure why the dealership couldn't have just moved the trim back to it's original location without replacing). All fixed now though...