johnrhopkins

In this 99 C4, the threaded plugs for the roof rack mount are not budging. It appears that a previous owner also wanted to put on a roof rack and broke two of them and apparently gave up. The two on the other side are in perfect shape but none of them want to budge.

I really don't want to drill and re-tap, but that might be the only option. Any other suggestions?

garrett376

Are you talking about the plastic flat-head screws? They should be easy to remove since they're only plastic.

johnrhopkins

I believe that the earlier 996 cars had metal ones. I had initially thought they were plastic as I'd read that elsewhere.

captain pabst

I just went through this on my 99. I ended up trying left hand drill bits, extractors everything no luck. Replaced all 4 with new. I wasn't confident in tapping or thread repair but i had nothing left from my attempts. Good Luck!

Ogr8frogy

Correct on early cars having metal threaded plugs, I think it was either 01 or 02 they changed them over to plastic.
I don’t know of anyone that has been successful in drilling and tapping them.
My 99 same way frozen in place.

johnrhopkins

Well, I tried drilling and extracting. The extractor broke off flush with the top of the screw. Haha. I'm worse off than before.

What part numbers did you buy and how did you do it? Those plates look like they are, at least glued.

Ogr8frogy

They are bolted in, you have to pull the headliner down to access them.
I have the part numbers somewhere maybe someone will chime in with them.
order them first then take them out other wise you have holes in the roof unless you park in doors.

jobyt

Any assistance with this would be HUGE. I have one still frozen in, and like OP, broke an extractor off in it.

DBJoe996

Maybe too late if the extractor is frozen, and those screws are the worst thing in the world to get out. Here is how somebody did it https://rennlist.com/forums/996-foru...t-problem.html

jobyt

That's how I did 2 of three; the extractor broke on the last one and I've put it aside. I may go back to it this weekend and re-drill this weekend with a smaller pilot hole.

chris8382

I tried using the extractor technique on my 99 C2 years ago. I was not tracking that you could get access from the headliner. I eventually damaged the extractors and had to drill/tap. I then replaced with plastic screws to prevent seizing again.

Now with my 03 C4S, I'll be sure to use the headliner access technique.

dporto

^^^ You're going to try to drill out an extractor/ez-out ? Good luck with that - those things are hardened steel... Please document your attempt - If it works, I'm sure there are many that would love to see this info! Good luck

Ogr8frogy

ok here you go guys

Roof Panel Plate - Porsche (996-504-911-00)

sunset Porsche parts is where I found this

johnrhopkins

If I had never tried the extractor, I'd have my roof rack on now.
I drilled and tapped the other three. I bought some cobalt bits and drilled out the extractor, but the hole I drilled on this one was a mm or so off from center. I did manage to drill the hole, but some of the extractor metal was still in there and when I got about 1/3 in with the tap, it snapped. So, thanks to Ogr8frogy providing the part number, I've ordered the replacement for that one. I have pulled away the trim bits/headliner from inside the car to expose the underside of the mount area. I just don't understand the instructions at this point (https://www.renntech.org/topic/5942-roof-rail-covers/).

It says: 8 Detaching base plate of Roof Transport System.
Release stud -10- from hexagon socket head bushing a/f 8 (micro-encapsulated) -12-. Remove the base plate -11- from the roof channel.

Anyone who has done this able to explain this a bit better? Do I just need to unscrew it from the underside with an 8mm hex? Doesn't seem to want to budge, but if that is it, I can hit it with an impact wrench. I just want to be sure before I take it too far and make things worse.

EDIT: After finding the picture in this thread: https://www.renntech.org/topic/16221...s-part-number/ I was able to see the threads and understood how it was engineered. I took an impact wrench to the 8mm hex on the underside and it unscrewed and came apart. Doing it without an impact wrench would have been a real chore. Now just need to wait for the replacement part to arrive.