MELISCAT
Member Since: 17 Dec 2009
Location: Macclesfield, Cheshire
Posts: 58
  
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| Roof Rail Failure on D3 SE |
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Has anyone else experienced failure of the roof rail fixings on Disco 3?
My D3 has a Hannibal rack and Columbus - Carbon fibre tent fitted - approximately 61Kg in weight.
A metal on metal noise has been traced by my main dealer to the front forward fixing on both passenger and drivers side of the factory fitted roof rails. The metal surrounding the captive nuts has sheared on both sides.
The car is still under warranty, but they are not sure if Landrover will cover this - I wait to find out as they suspect Landrover will want to replace the whole roof! 
They are going to send me some photos of the damage, I will post them when I receive them.
In the meantime if anyone else has had the same problem please contact me.
Mike Mike
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 Wed Jul 28 2010 8:44pm |
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MELISCAT
Member Since: 17 Dec 2009
Location: Macclesfield, Cheshire
Posts: 58
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Photo of failed roof fixing
 
Any comments?
Still awaiting Landrover's decision. Mike
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| Fri Jul 30 2010 9:45am |
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CFB
Member Since: 02 Dec 2005
Location: West Yorkshire
Posts: 4738
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Ouch, they might argue that the weight/load spec has been breached. Not sure what the figures are but with the rack, tent etc on then add the person or persons in it it might well have been overloaded (no offence meant ref your weight  )
Good luck 
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| Fri Jul 30 2010 9:57am |
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Baben
Site Sponsor
Member Since: 15 Feb 2006
Location: Kyalami
Posts: 1905
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That looks so weird!
Surely this damage could not happen if the bolts had been tight? It looks like the bolts were loose, and there was downward pressure on the captive nut, which it would not have been designed to handle.
What I mean is, the fixing is designed to be used in compression (ie. holding a load tight against the roof) and it looks like it has separated from the roof because it has been pushed downwards in the opposite direction. If I am not mistaken, the rails carry the load along their entire length, not just at the bolts, hence the bolts are just holding the rails in position. Or am I mistaken?
I suspect LR are going to blame whoever fitted the rack to the rails. Hope I am wrong for your sake.
You could probly fix this without too much trouble though - get rid of the rust, make sure the paint is sealed on the outside, strengthen the surrounding area under the roofwith a big washer, and add some loctite and bolt the sucker tight Unlock your 4x4 info, voice control, 3-flash indicators, sort out your leaning suspension, Bluetooth pairing, D3, D4 and RRS 
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| Fri Jul 30 2010 10:24am |
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zarnd
Member Since: 23 Apr 2010
Location: Kent
Posts: 622
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Ouch! Not good at all. Fingers crossed it is covered though!
cheers and good luck Alex
2007 07 Reg D3 TDV6 HSE
2005 54 Reg Mini cooper S
2002 02 Reg BMW M5
1989 G Reg Golf GTI
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| Fri Jul 30 2010 10:39am |
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lee157
Member Since: 01 Oct 2008
Location: in the middle
Posts: 374
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Very interesting, the only difference between yours and mine is i have the glass roof, but the fixing points for the roof rails are completely different and span a wider area. On the glass roof the rails actually sit on the 3 mounting points aprox 5mm above the gutter.
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| Fri Jul 30 2010 10:56am |
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DSL
Member Since: 11 May 2006
Location: Not here ^^^^ :(
Posts: 22710
 
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Wonder if they ran out of proper fixings on the production line and just made do with whatever was available.  Can maybe be ar$ed a bit.
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| Fri Jul 30 2010 11:09am |
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MELISCAT
Member Since: 17 Dec 2009
Location: Macclesfield, Cheshire
Posts: 58
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Hi Guys, to answer a couple of questions, the roof loading is a Dynamic loading not a static one, as far as I am aware the dynamic load for the roof is 75Kg.
The roof rails were factory fitted at Landrover when I ordered the D3 Mike
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| Fri Jul 30 2010 8:47pm |
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RLD
Uncle Ray
Member Since: 18 Jul 2005
Location: could be some where els'e
Posts: 7326
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then Land Rover should pay out Home of RLD Hidden winch mounts and soon external mount Tree and Rock Sliders Jerry can Holders Spare wheel Locks Off Road Towing Hitches Sankey Trailer Body Fabrications and much much more and keeping a look out for santa
more Helsport tents and other things for camping 
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| Fri Jul 30 2010 8:50pm |
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Discoeast
Member Since: 19 Feb 2008
Location: Boksburg
Posts: 769
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MELISCAT, that is sad to see and I hope it gets sorted. Could
you perhaps find out the build date of yours.
This raises a question, how many D3's have been butchered this
way and is there a way to identify the vin No's affected so others
can be warned of a possible failure if a RR is fitted. For those
whom have a RR fitted to get the mounts checked ASAP.
looking at the pics, this could be the start of a recall.
I'd love to get my hands on this idiot and shove his design drawing
where the sun don't shine  D3 bullbar-spots-roof rack with spots-ladder-long range tank-swing out spare wheel carrier- upgraded tow bar-dash console-internal water tank-duel awnings-drawer system & T T.
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| Sat Jul 31 2010 8:12am |
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gilmore
Member Since: 16 Jan 2005
Location: On the sofa
Posts: 1915
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I didn't get all that about static vs dynamic load.. So can you clarify whether the max load has been exceeded? If it has then LR shouldn't have to pay. If you haven't exceeded the max load then they should.
Simples.
regs
rob All opinions expressed in this posting are my own and are not necessarily those of someone who knows what they are talking about.
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BMW 330d M Sport Convertible
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Waiting for the Discovery 5 HSE
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| Sat Jul 31 2010 9:16am |
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caverD3
Member Since: 02 Jul 2006
Location: Sydney
Posts: 5165
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Looks like wrong fixing. The not will crack the steel as it is too small resulting in higher pressure, stress fracture will eventually happen with any load. There would be a reason for the change in fixing. Is there an easy way to look at the fixings without removing headliner? "A society that will trade a little liberty for a little order will lose both- and deserve neither"
Thomas Jefferson.
TDV6: Adaptive Headlights, Electronic Rear Diff, ARB Bar, Blaupunkt Speakers, JVC Powered Subwoofer, Removable Snorkel, Mitchell Bros Tow Hitch, Pioneer After Market Head Unit, Zenarc Touch Screen, In Car Sub-notebook, GPS Anntenna, Steering Wheel Control Adaptor, Remote Adjustable Supension Rod System, Taxside Dual Battery System.
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| Sat Jul 31 2010 11:52am |
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gilmore
Member Since: 16 Jan 2005
Location: On the sofa
Posts: 1915
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NeilD wrote:Dynamic Load is ... the load when moving......
Static Load can be therefore more. I.e. a rack + two man tent + two actual men...... more like 300kg
Thanks very much. Got it now.
cheers
rob All opinions expressed in this posting are my own and are not necessarily those of someone who knows what they are talking about.
Mercedes ML350 Sport.
BMW 330d M Sport Convertible
Honda CRF250X, CRF150RB, KTM 85sx
Waiting for the Discovery 5 HSE
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| Sat Jul 31 2010 2:01pm |
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