Sunroof

1fastredsc · 02-19-2004, 09:29 AM

So i took the tarp off the car, washed it and brought it back into the garage (almost time to put the motor and tranny back in). I started to fiddle with sunroof to try and figure out why it doesn't work. Found out that the PO chopped the wires going to the sunroof motor. So i reconnected the wires only to find out why they chopped them.
The motor now works, but the sunroof won't budge. Under closer observation, it seems that the contact between the gear and the spiral cable is skipping teeth. And although the cable moves some, at some point they just stop and the gear skips. Plus the sunroof won't even attempt to budge even though the cables are moving a little bit. Any theories as to where i should look?

Wil Ferch · 02-19-2004, 11:24 AM

I believe there is a R&R article in the Rennlist archives on just this topic.
you'll likely have to upgrade to 964 cables ( older versions are NLA)...and, as is the case with those clever Germans...the new cables have to be modified to fit...the front foot ( or such) won't fit and will have to be hand- filed down. You may want to start the disassambly from the zippered headliner near the back where the motor is...and take it from there with the archived article in-tow. Sorry, don't have it in front of me...

--Wil Ferch

john walker's workshop · 12:02 PM

if the rear of the roof won't drop down normally, due to broken cables, pop the front of the sunroof headliner down and slide it into the pocket. (a putty knife helps to get under the front edge). remove the 2 motor screws, pull motor down and let it hang. get a flashlight and find the overcenter levers on each side of the sunroof, toward the rear, and pop them rearward with a screwdriver and your palm, which will allow the rear of the sunroof to drop. remove the 2 front slider pieces, and remove the screws from the small rear plates which attach the roof to the cables, and pull out the small plates just under the screws. lift the front of the panel from underneath and remove the panel. remove the screws and misc items from the side rails, and both front corner sections (early), or the whole front wind wing (late), drill out 2 pop rivets in the side rails (late only), lift the front of the rails and pull out the cables. by then you will have found the problem. best not to lube anything on reassembly, as grease just attracts dirt.

niner11 · 02-19-2004, 12:50 PM

just wanted to add that if you need to replace your sunroof cables it is not necessary to upgrade to the newer rails. The 964 cables can easily be modified to fit earlier 911's. Dremel or grinder works well. Good luck.

1fastredsc · 02-19-2004, 01:35 PM

Thanks guys, i'm going to have to get clever with my sunroof as there is no zipper to access the rear motor. I had to it taking the roof interior lining out partially to get to the motor as is. Thanks for the advice john, i'm going to print out your instructions and see if i have the edumacation to follow it

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1fastredsc · 02-23-2004, 07:15 AM

Is there a special way to to get the roof material back into the rear window rubber lining? Is there a special type of adhesive to use to get it to stay there?

john70t · 10:07 AM

Mabye a small edged metal scaper to lift the seal, and another to push the felt in?
Use office clips to hold it place while drying. 3m weatherstipping is strong, but way too stringy and too short a dry time to use for this app. Rubber cement wouldn't be strong enough. Not sure about the glue.
I re-did a 87 golf headliner(foam shelled) that was cracked and hanging by:
spreading bedsheet on both sides with 3m foam-fast(anything else will melt it) until dry to stiffen, then recovered the whole thing with thick dark grey fabric from a second hand store held in place with 3m general purpose spray. Was pretty nice.