Thanks for taking the time to post your message:
The new rails seem more durable...
I am guessing you work at Subaru and this is hands-on information. Valuable!
I have a 2015 Outback 3.6R that is starting to exhibit this problem. I am using the roof rails heavily, and needed to build my own steel rails as shown here (they bolt down into the Subaru tie-down plates):
http://www.subaruoutback.org/forums/138-gen-5-2015-present/241545-detailed-parts-diagram-2015-outback-roof-rails.html#post2938810
I have a >3000 km trip upcoming, and the rack will be full. Since the "old" Subaru rack *seems* to be strong enough for the time being, I have to decide between:
a) Get the new roof rails now, and hope they are installed properly, and don't create new problems (e.g. squeaks from the headliner reinstallation)
b) Do the trip with what I have now because if it ain't broke, don't fix it (yet)
May I ask, what you would do?
Regards,
Jean Goulet
Canada