Sunroof Problems

[ned903]

I’ve been lurking around this site for nearly in year now getting my nerve up to purchasing my first 911. In May I finally took the leap (I hope not over a cliff). To say that you have all been helpful would be a serious understatement! I’m sure I would not have made the decision to buy if I had not had the encouragement from this board. Ok, now you are all responsible for whatever happens!

My car is a 1987, sunroof coupe in Venetian Blue. It has about 85,000 miles on it. I got a good PPI from Mayo before purchase. I am at work and do not have photos of my car handy, but I will post them later.

Now to the problem. About two weeks ago I attempted to open the sunroof. It opened a short way and then stopped. Repeated attempts led to the same result. I investigated the postings on this board, read the technical papers and dove into the project. As expected, the passenger side cable had disconnected from the fitting. It appeared that this had happened at least once before and a previous owner had made a crude effort to repair it. Being from east Texas I did what we do to make any repair, I got out the JB Weld and glued the cable into the fitting. This was allowed to cure for a week or so while I awaited some small parts I ordered from our host.

Last night I reassembled everything and was pleased with myself to find that all was well until about the third time I tested my work. Suddenly, the roof stopped opening all the way just as it had before. Assuming that my repair had failed I disassembled the roof. What I found perplexes me. The repair is sound. Everything works until the roof panel is put back in place. The roof will open a couple of inches and then binds up. It appears that it opens slightly further on the passenger side.

Anybody have any advice?

[KevinP73]

It sounds like you don't have the cables "equal" to each other. Or I'd check for a kink in one of the cables that might be binding as it enters the gear drive in the back. Most important also is to clean and lube EVERYTHING in the system. Remove the cables the track the gear drive and re-install properly.

[Cdnone1]

Is your sunroof headliner sliding correctly. That happened to me. Try assembling without the healiner and see if it opens. If it does then you know that the headliner is causing it to bind.
Steve

[ned903]

Thanks, guys. You have given me good ideas. I'll be in the car shortly to try them.

Also, I've posted the photo I promised.

[vytenis]

There are two (2) white plastic clips on the front of the sunroof. If one or both are broken, the front lip of the sunroof catches and can bind.

[ned903]

Thanks everyone. It appears that vytenis nailed it! Next time I'll order all of the little parts!

[curlesw]

Can you post a pic of the culprit...I have the same problem.

v/r
Wayne C.
83 SC

[ned903]

Getting a photo would require that I disassemble the sunroof (again!!!). It’s a simple thing, but I’m not going to do that until I get the needed part., however, look at the tech article on this site.
http://www.pelicanparts.com/techarticles/911_sunroof_repair/911_sunroof_repair.htm

Figure 9 clearly shows the item in question. The culprit is the white plastic square. What was happening was that the black plastic wind deflector hinge was catching on the edge of the sunroof because the plastic protective edging as Pelican refers to it (901-564-433-05-OEM was missing.

I believe that all of the suggestions I was given were valid and could have explained the problem. My suggestion is that this is enough trouble that I would plan on replacing all of the small plastic parts at the same time.

Good luck.

[ned903]

When I added my last post to this thread I thought I had all I needed to know about this situation. I even posted a link to Pelican's technical info showing the parts in question. Following this post, I ordered the parts from Pelican for a 1987 sunroof. I was curious in that the catalog said that four were required and I could only find evidence of two. The parts arrived and I again stripped down my sunroof. Much to my surprise, the pads in my roof were not the same as those provided by Pelican. It appears that my car has either had a replacement sunroof panel (no evidence)or some type of running change was made(you gotta love it).

About this time I had the car to Mayo for some minor repairs. They were able to source the correct parts for me ( as, I am certain, Pelican could have). I have attached a photo of the correct parts. I suppose the lesson is that these cars are a trip, not a destination!

[RoninLB]

I had to fab an install of those white plastic sliders when I installed the one piece air deflector and mechanism to replace the aluminum ones. Old deflectors don't use them.

[vytenis]

These clips are available at Porsche dealerships and are the least expensive parts I've gotten there. 89 cents each, I believe.

[defcon65]

FWIW, Wayne's 101 projects book covers sunroof adjustment, repair and lubrication, with pictures...

[jorian]

Porsche manuals state emphatically NOT to lube the tracks!

[defcon65]

Looks like mine has been lubed with white lithium - maybe by PO. Works great, though.

[ned903]

defcon65,
I lubed mine with a light coat of lithium and it seems to work fine.

[RoninLB]

I didn't lube mine as it attracts abrasive and jamming dirt.

if I did feel a need to lube the tracks I'd use that spray can motorcycle chain lube that dries.