BennyLumpkin
Active LVC Member
Ok guys this question has come up alot and thanks to BigRigLS I picked up the sunroof repair kit from the Sunroof Doctor. Here is a picture step by step I hope gets made into a sticky as it seems to be a popular subject.
Step 1. Remove the glass. There are 4 torx bit screws, two on each side you have to access from the inside of the car. Pull all 4 and lift the glass up and out....easiest when you have someone to hand the glass up to.
You'll see by the bent slide rods mine was pretty FUBAR.
Step 2. Remove the headliner. I didn't get a good pic of this but its pretty easy. Pull all 4 corner pillar trims off, the trims where the seatbelts attach, all 4 oh crap handles and the sunvisors and clips. The visors will hang by their wire which you can't unplug until you drop the liner down and you can get them. There is a plug glued on both corners of the headliner and you have to disconnect them there. The only thing left holding the liner is heavy duty velcro around the headliner opening and 2 clips above the lights/sunroof switch. Use a long flat screw driver to spread each velcro apart and also use it to release the clips. This is again a two person project. Lay the seats back a bit and just lay the headliner on the seats/dash and let it there. Once its down there are 7 bolts holding the sunroof assembly and 1 wire plug on the passenger side. Start by unhooking the drain tubes from each corner, then unplugging the wire plug and then take the front 3 bolts, the next two back from that and the 2 farthest back. Save the middle two for last. I used a drill with a socket adapter and it worked great. Bolts are 10mm. Once they're all out just bring it out either the drivers or passengers front door.
Step 3. Remove the motor and the driver assembly from the rest of the sunroof track. One side has 3 torx through the motor. Remove them first. Then there is one on the other side so take it out next.
Step 4. Drill the 4 rivets out of the rear of the track drains. On each side there is a black plastic piece (pictured). There is two rivets in each one. Drill them out with a 3/16 drillbit and carefully pull them off as they are glued on.
Step 5. Remove the old parts. Start with pulling the torx on each side that holds the crossbar that actuates your headliner off.
Then take one side at a time and pull the parts backwards and out of the track. Now is a good time to clean the track with brake clean as the kit comes with new grease for the track.
Step 6. Go back together the way it came apart....only better. Put the parts back in, the way they came out...pretty simple to follow. TAKE YOUR TIME! Some of these parts are plastic and could probably be broken easily. Slide each part in and put them together the way they pulled apart.
Should look like this:
Step 7. After all parts are back in place including the headliner(the sliding part)....I had to drill the rivets out a second time because I forgot it lol....then its time to "time" the roof assembly. First thing to do is flip the motor actuator over so you're looking at the gear and to the side of it is a little window with a white backround. Spin the gear around until you see a black dot in the very middle of that window and then install it, and the motor back to the rest of the assembly...you make have to pull this back apart after testing the roof if you don't have it quite right.
Step 8. Rivet the ends back on after making sure all parts are in place.
Step 9. Double check your work
Step 10. Install the unit back in the car.
Step 11. After making sure everything is in place, DO NOT TRY THE SUNROOF YET. Do not install the headliner yet. Install the glass and then make sure the roof is in the closed position. You can run it back and forth at this time. Once it's in closed position you may have to loosen those 4 screws up and flush the glass to the roof so it is closed and sealed correctly.
Step 12. Install the headliner and enjoy!
Step 1. Remove the glass. There are 4 torx bit screws, two on each side you have to access from the inside of the car. Pull all 4 and lift the glass up and out....easiest when you have someone to hand the glass up to.
You'll see by the bent slide rods mine was pretty FUBAR.
Step 2. Remove the headliner. I didn't get a good pic of this but its pretty easy. Pull all 4 corner pillar trims off, the trims where the seatbelts attach, all 4 oh crap handles and the sunvisors and clips. The visors will hang by their wire which you can't unplug until you drop the liner down and you can get them. There is a plug glued on both corners of the headliner and you have to disconnect them there. The only thing left holding the liner is heavy duty velcro around the headliner opening and 2 clips above the lights/sunroof switch. Use a long flat screw driver to spread each velcro apart and also use it to release the clips. This is again a two person project. Lay the seats back a bit and just lay the headliner on the seats/dash and let it there. Once its down there are 7 bolts holding the sunroof assembly and 1 wire plug on the passenger side. Start by unhooking the drain tubes from each corner, then unplugging the wire plug and then take the front 3 bolts, the next two back from that and the 2 farthest back. Save the middle two for last. I used a drill with a socket adapter and it worked great. Bolts are 10mm. Once they're all out just bring it out either the drivers or passengers front door.
Step 3. Remove the motor and the driver assembly from the rest of the sunroof track. One side has 3 torx through the motor. Remove them first. Then there is one on the other side so take it out next.
Step 4. Drill the 4 rivets out of the rear of the track drains. On each side there is a black plastic piece (pictured). There is two rivets in each one. Drill them out with a 3/16 drillbit and carefully pull them off as they are glued on.
Step 5. Remove the old parts. Start with pulling the torx on each side that holds the crossbar that actuates your headliner off.
Then take one side at a time and pull the parts backwards and out of the track. Now is a good time to clean the track with brake clean as the kit comes with new grease for the track.
Step 6. Go back together the way it came apart....only better. Put the parts back in, the way they came out...pretty simple to follow. TAKE YOUR TIME! Some of these parts are plastic and could probably be broken easily. Slide each part in and put them together the way they pulled apart.
Should look like this:
Step 7. After all parts are back in place including the headliner(the sliding part)....I had to drill the rivets out a second time because I forgot it lol....then its time to "time" the roof assembly. First thing to do is flip the motor actuator over so you're looking at the gear and to the side of it is a little window with a white backround. Spin the gear around until you see a black dot in the very middle of that window and then install it, and the motor back to the rest of the assembly...you make have to pull this back apart after testing the roof if you don't have it quite right.
Step 8. Rivet the ends back on after making sure all parts are in place.
Step 9. Double check your work
Step 10. Install the unit back in the car.
Step 11. After making sure everything is in place, DO NOT TRY THE SUNROOF YET. Do not install the headliner yet. Install the glass and then make sure the roof is in the closed position. You can run it back and forth at this time. Once it's in closed position you may have to loosen those 4 screws up and flush the glass to the roof so it is closed and sealed correctly.
Step 12. Install the headliner and enjoy!
