Kia Sorento XM Platinum MY2011 roof rail corrosion / removal / install

Corrosion has occurred in my 2011 Kia Sorento cast alloy roof rail mounts. As the vehicle is out of warranty Kia Australia do not consider it their problem.
From online investigations, it appears Kia UK recognised the issue some time back. Electrolytic or galvanic corrosion in this case is caused by dissimilar metals in contact and is the result of poor design and assembly techniques. When i removed the brackets, the steel mounting nuts had clearly removed the layer of paint on the aluminium alloy brackets during assembly.
The reason I show removal of the plastic bracket cover after I had sand blasted and re-coated and re- installed the brackets, was because the original video footage was faulty.
The powder coating has provided a hard thick protective coating but struggled to cover the deep pitting from the corrosion. I will be interested to see if I have a repeat of the issue.
I was quoted approx A$900 for supply of 2 new rail assemblies (separate parts not available)

[@DavidBrown-vc7cp]

Thanks mate, just found this - exactly what I needed to know to deal with my Kia Sportage - though they have a slightly different design and I could pull them off by hand. Till I saw this I didn't even know the COULD come off with relative ease - in my case very easily

[@lostsoul3154]

THANK YOU!! Will have to take mine off for repainting.

[@80spyder1]

Did you paint that silver end cap that you removed. I was hoping you would mention what the color code was I can’t seem to find that anywhere.

[@michaelgorski169]

Thanks for your help 👍

[@jaycee7735]

did he say turbo diesel??

[@davow8]

Yes Johnny. A 2.2 litre common rail turbo diesel. Great motors but not sure that they are available in the USA. We have the 3.5 litre V6 petrol/gasoline version available in Australia also but only in front wheel drive.

[@Careerextendersmassagetools]

Where did you get the "side rails", and the front tubing with lights. They look great! I can't find them online. thanks Merrill

[@davow8]

Australian aftermarket manufacturers which have to comply with Aussie Design Regs. They were on the vehicle when i purchased second hand. Other countries possibly have different design regulations. The side steps can be useful when washing the car (roof) and tying off loads on the roof bar but can be a nuisance getting in and out if you have short legs. The front alloy 'nudge' bar is handy for holding lights but offers minimal protection if you hit a larger object eg kangaroo. As I have done. The steel brackets which clamp it to the sub-frame tend to rotate and the whole thing gets pushed into the plastic work. It also makes a mockery of pedestrian impact design which all vehicle manufacturers have to comply with. Otherwise thankyou for the compliment Merrill.

[@delmarray1147]

I went to get in the car and the whoe thing came off. Is there a way to put it in back on

[@davow8]

You mean the plastic end cover?

[@delmarray1147]

Yes the roof rack

[@davow8]

Sorry. I don't understand what your issue is. The plastic end caps are held on by a combination of metal and plastic clips. If they have broken or been lost you may need to order a replacement part. The roof rails are held onto the vehicle by 4 permanently attached studs and nuts per side. If you have a roof rack attached to the side roof rails and the entire assembly has come off you have a problem greater than I can fix here without more details and photos. I would suggest you take it to a garage. @@delmarray1147

[@juniorcruz469]

Nice. You guys got turbo diesel. Power?

[@davow8]

Gr8 motor and responsive power delivery from down low. Around 145KW and 430Nm.

[@richardramsay830]

I have roof rail corrosion on the ends of one rail. This vehicle has been in Alberta all its life (2013) so salt from the ocean isn't the cause it instead it is poor material used in making the rails. They need to stand behind this problem.

[@davow8]

If it is still under warranty I would certainly press for replacement Richard. I am happy for you to show them this clip.