XTR Offroad 5th Gen 4Runner Roof Rack — Overland Rack (2010-2023)

This is a DIY, no-drill install. You build the rack on the ground, bolt and seal the brackets to the roof, then set the rack on the brackets. The illustrated instructions walk through 12 steps.

How Long Does Installation Take?

Times are hands-on time for a first install. Add the 8-hour sealant cure explained below. Attaching the crossbars to the side fairings takes the most time for one person, because you hold a 50 in bar against a standing side fairing while starting the screws. With two people, one holds the bar while the other starts the screws, which is where most of the time is saved.

The One Step That Needs a Helper

Lifting the rack onto the roof. The assembled rack is about 60 lb and 50 × 95 in, and the 4Runner's roof is about 6 ft up, so plan on a second person for roughly 10 minutes.

Plan Around the 8-Hour Sealant Cure

Don't load the brackets until the RTV sealant has cured for 8 hours. Following the steps in order, that means an 8-hour pause between Step 9 and Step 10. To finish in one day, install and seal the brackets first (Steps 8–9), then build the frame on the ground while the sealant cures.

Tools and Supplies

• 4 mm and 2.5 mm hex keys
• 10 mm and 5.5 mm wrenches
• Socket for the factory M8 roof bolts
• Torque wrench
• Tape measure
• Plastic trim tool
• Black RTV silicone (Permatex 81158)

It fits the 2010–2023 Toyota 4Runner (5th generation). It bolts to the factory roof mounting points at the middle and rear of the roof, the same points the factory roof rack uses. If your 4Runner has a factory rack, it comes off; if not, you remove the plastic covers over the mounting points. Two versions are available: a standard front fairing, or a front fairing with a cutout for a 40 in light bar.

No drilling and no cutting. Four brackets bolt to the 8 factory mounting points with Toyota's own M8 roof bolts. Two front supports rest on the roof near the windshield and are not bolted. To go back to stock, unbolt the brackets, clean off the sealant, and refit the factory rack or covers. Remove the covers slowly during install, because their plastic clips can break if forced.

Every mounting point is sealed. Each one gets an aluminum bushing with black RTV silicone on both faces, and the factory bolt passes through the sealed bushing into the factory threaded hole. The RTV cures for 8 hours before you load the rack or drive. The instructions protect your paint at each step:

• Clean each mounting point so the seal bonds.
• Assemble the rack on a padded surface, not on the truck.
• Lift the rack onto the roof with two people.
• Lower the front supports until they just touch the roof, never forcing them down.

Yes, with a helper for about 10 minutes to lift the rack onto the roof. A first install takes about 3½–5½ hours solo, or about 2¼–3½ hours with two people working together. Either way, add an 8-hour cure for the RTV sealant before the brackets can carry the rack. See the installation section above for the time breakdown and tool list.

Measured at the roof mounting points, the top of the rack sits about 3.0 in above the roof at the front, 3.5 in at the middle and 3.7 in at the rear. Its highest point, at the back, is about 3.8 in. Nothing sits above the crossbars, because the fairing tops are level with them or lower. The roof is higher in the middle than at the mounting points, so your 4Runner's overall height goes up by less than these figures.

Add up three heights: your 4Runner's stock height, the rack's added height, and how far your tallest accessory rises above the crossbars. Compare the total with the lowest point of your garage opening, including the door, track and opener. Do the same check for drive-thrus, parking garages and car washes.

The rack is rated for 400 lb dynamic (driving) and 800 lb static (parked). The rack itself weighs about 60 lb. Toyota's roof load limit in your owner's manual covers the rack plus everything on it, so the rack's own weight counts against that limit. The load reaches the roof through the 4 brackets on the factory mounting points; the 2 front supports only rest on the roof.

The deck is flat from side to side, with 10 crossbars spread over about 86 in of roof. Tent rails or brackets bolt into the top T-slots with M6 or 1/4-20 T-slot hardware, and four crossbars (3, 6, 7 and 8, counted from the front) can be moved to suit your tent's rails. Useful crossbar spacings, center to center:

• 36.6 in: bars 5 and 9, directly over the roof brackets
• 49.0 in: bars 4 and 9
• 71.6 in: bars 2 and 9

Check your tent's weight against the load ratings above, and remember that the rack's own 60 lb counts toward your 4Runner's roof load limit.

The crossbars are 1020 aluminum T-slot, 2 in wide and 1 in tall, with 6 T-slots each: 2 on top, 2 underneath and 1 on each edge. Accessories made for 10-series T-slot hardware (M6 or 1/4-20) mount directly, as do clamps that fit a 2 × 1 in bar. The side fairings cover the ends of the bars, so to add hardware after assembly, use drop-in (twist-in) T-nuts such as our 1/4-20 10-series drop-in T-nuts, or slide nuts in before the fairings go on. Under the bars there's about 2.0–2.7 in of clearance at the roof edges and less toward the middle, so keep anything mounted underneath clear of the moonroof. For lights, the light-bar front fairing has a cutout for a 40 in light bar.

The platform carries its load into the roof through bars 5 and 9, which sit on the brackets 36.6 in apart. Everything else is what the platform adds: room for several accessories at once along 86 in of roof, a flat deck for boxes, cases and tents, and fairings across the front and down both sides. The trade-off is weight: about 60 lb of your roof load limit.

The rack is designed to stay quiet up to 80 mph, even in a headwind rainstorm. The front fairing ships with a seal already applied to cut wind noise. A full-width front fairing sits just below the top of the first crossbar, and side fairings cover every crossbar end, so air goes over the deck instead of across open bar ends. Accessories that stand tall near the front of the rack can add noise.

Any roof rack adds some weight and drag. This one sits low, about 3.0–3.8 in above the roof at the mounts, and is faired on three sides. Cargo on top usually has a larger effect than the rack itself.

Yes. The crossbars are powder-coated aluminum, the hardware is stainless steel, and every roof mounting point is sealed. Check the hardware and seals on the maintenance schedule below.

The rack lifts off in one piece. Remove the 8 M6 nuts (10 mm wrench) that hold it to the roof brackets, then two people lift it off. The brackets stay sealed on the roof, ready for the rack to go back on. To remove the brackets too, unbolt the 8 factory roof bolts, clean off the RTV silicone and refit the factory rack or covers.

We don't recommend automatic car washes, including touchless washes. Brushes and cloth strips can catch on the rack and any mounted gear, and the strong detergents used in touchless washes can wear on the finish. Hand wash the rack with mild soap, water and a soft cloth or brush.

• Crossbars: 1020 aluminum T-slot with black powder coat
• Fairings, brackets and reinforcements: high-strength aluminum
• Hardware: black stainless M6 button-head screws, stainless Nylock nuts, 304 stainless carriage bolts and stainless badge hardware
• Mounting bushings: aluminum, sealed to the roof with RTV silicone

The rack is backed by our limited lifetime warranty.

• Re-check all hardware 30 days after your first drive, then once each season.
• Inspect the RTV seal around each roof mounting point.
• Replace any Nylock nut that spins on freely. Their nylon inserts lose grip after repeated removal.

Not as standard. The rack and T-slot accessories use standard hex screws and nuts, so gear can come off with a 4 mm hex key or a 10 mm wrench. Lock valuable gear with its own locks.

Estimated lead time is 4–6 weeks. The rack ships unassembled; its longest part, the rear side fairing, is about 59 in long.