Not uncommon. You'll need to enlarge the hole in the sheetmetal so the bolt will clear. Not an indication of bigger issue other than Ford has a production tolerance problem.

All the best,
Hein
DIYvan

 

I also needed to tap my threads to clean them up. I think it was largely paint in the holes and they were easy to do but I couldn't get bolts in otherwise.

agreed to both. We had to do both of these for a few holes.

 

Watch this video.....

 

Enlarging the hole is going to be more productive than battling the Ford windmill.

 

I also needed to tap my threads to clean them up. I think it was largely paint in the holes and they were easy to do but I couldn't get bolts in otherwise.

 

Is there a certain size you used to tap the threads?

 

Very common problem for last couple years that I'm aware of. I have installed many ladder racks on the Transits over the last 3 years and I honestly do not remember once not having miss-aligned holes. This is just an expectation when installing anything on a Transit roof.
Walk up the ladder with the following tools every time I install a ladder rack.
Razor knife or scraper .... to remove the caps / stickers from atop the factory holes
Step bit ... to elongate the roof sheet metal to line up with the threaded hole
Sealant ... around and through every threaded hole. Avoid ANY water penetration NOW
Roof rails .... Tape measure ... tools .... and ladder rack

 

Step bit ... to elongate the roof sheet metal to line up with the threaded hole

That's a smart and easy solution!

 

Thanks for the info, got out my Dremel and fixed it. The drivers side was perfect, so I was surprised to see it so far off. Yet another example of things taking me 3 times longer than expected

 

Some would Say Dicor self-leveling for that horizontal surface. I prefer Proflex and use it on my TT as well. I left all the caps on the roof that I wasn't going to use and covered over with some clear Proflex. For the 4 I did use I fortunately did not need to tap to be able to thread a bolt for the DIY Van V2 roof rail brackets. Since they came with a neoprene washer I didn't use any sealant there as per Hein's advice and there have been no leaks.