Weak motor?

[Matt7084]

I completely disassembled my sunroof top to bottom, cleaned the rails and cables with hot soapy water and dried them, reassembled everything, replaced the little clutch piece...

The cables moved back and forth perfectly and in synch.

But now that ive attached the sunroof back on it cant move it into the up position, it hits the visor arms and just stops dead in its tracks. Nor can it pull away from the closed position.

The hand crank works it back and forth fine.

Could the sunroof motor not be strong enough for some reason? What could be the problem here?

-Matt

[Groesbeck Hurricane]

did you clean the electrical connections? Motors do go out.

[Paulporsche]

There are disks inside the gearbox which are immersed in a thick greasy fluid (viscous coupling?). Maybe your disks have worn or some of the fluid has dried or evaporated.

There is also a metal gear inside which wears out. Maybe the gear has lost some of the edge off its teeth or has started spinning on its shaft.
You can pry the metal casing open and check inside.

[Matt7084]

could you elaborate on prying the metal casing open? A long look at it and a quick attempt with plyers didnt yield much...

thanks and I do think it could be that piece (but something inside it, because the teeth on the outside seem to be intact)

-Matt

[Paulporsche]

Matt,

I had to scan the memory banks on this one. I think I took it apart over 10 yr ago. The gear is on the outside, and the teeth round off. They look OK but they don't work as well as a new one.

You replaced the clutch, which is a rubber (?) tube that connects the transmission w/ the motor. Does that clutch slip on the shafts? I think ther is supposed to be some slipping.

To get inside, I think you have to pry up some crimps in the metal housing w/ a strong knife blade or a chisel or screwdriver. The disks are inside in a bath of something. I can't remember if it was a grease or a heavy weight oil. If you open it up, please let me know.

Have you checked the ratcheted arm on the end of the cables. These rock up into position bringing the back of the panel up.

I think I turned the disks inside the trans around to provide new mating surfaces, refilled the fluid, and closed up the housing. I then replaced that gear. The things works almost like new, although I usually help it along by pushing it up @ the rear just a little @ the end of the run to bring the panel up to the exact height.

I may have replaced the fluid w/ something other than original , using what I had @ the time, which is why I would like to hear your description of what it is. If you can replace the fluid or use something identical, your repair may work even better than mine.

[Matt7084]

ooo thats the other thing, something could be messed up with the ratcheted arms that push the roof up, seeing as thats where the sunroof stops functioning.

I see what you mean about having to pry open those crimps, ill work on it tomorrow and reply with pictures

thanks

-Matt

[Matt7084]

Last ditch effort here, then im selling this car with a broken sunroof...

Take a look at this pic and tell me, maybe i reassembled this part wrong.

FYI - ive twice completely disassembled and reassembled every part of the sunroof, cleaned it, lubed it, made sure it was working properly and i still cant figure out whats wrong

-Matt

[Paulporsche]

Matt,

I am trying to remember from quite a long time ago, but here goes.

I think the 2 grooved pieces are wrong. Is there only 1 smooth and 1 grooved side to each? I think the part closest to the camera should be turned around so the grooves interlock.

Are you able to align the 2 grooved pieces so the grooves are in sync? I think you can push the upper on all the way up and then interlock the grooves so they hold together. Do you have the lower one turned around so the grooves do not interlock? I don't think there should be a smooth side against a grooved side. This allows for adjustment, alignment and it secures them.

Do you have a shim piece of steel that goes between the piece you are holding and the panel? I suppose you could also shim between the part you are holding (w/2 holes) and the panel w/ washers if you have to. Don't forget to clip the spring metal on the panel over that rod. Make sure non pivoting parts are snugged down.

Let me know if this helps.