New issue, same problem

[pfarah]

So here's a new one... Since replacing my entire sunroof electrics and mechanical assemblies, the sunroof still doesn't work so I decided to shelve the problem until next spring by manually securing the roof (using the supplied tool). The crazy thing is that when I drive (from stop to about 5 mph), the circuit opens the roof a tiny bit (actually it just loosens the arms by about a 1/4 inch). This drives me nuts as now the roof whistles while driving and keeps repeating if I re-secure the roof panel manually. I don't want to lose the remote rear hatch release operation so removing the fuse is out. What can I do to stop the arm locking circuit from activating? I've researched Clarks as well as the factory service manuals with no luck. Any suggestions??? Thanks!

[Rasta Monsta]

Arms are out of adjustment relative to the cables. The car thinks the arms are fully retracted (like you just reinstalled the roof) as you drive off, so it runs them out to the "fully down" position. Once it does this, pop the covers and move the arms so they are resting at the "high spot" in their tracks.

[Sehrgut]

Hey pfarah,
My '84 had the same problem after I manually operated the sunroof. I finally discovered that the cable dog that activates the limit switches was broken. It is the little plastic piece that attaches to the end of the drive cable at the end of the car, I couldn't find one for our year car, so I cut a newer one (85.5 up) and modified it to slip on the cable end. I adjusted the Limit switches so the cable dog just touched the and the problem was solved. Pretty easy fix once the problem was diagnosed. Hopefully you only need to adjust the limit switches. Good luck and let us know your results!

[massive]

You should read my how to thread on the 944 sunroof, might help you 944 Foot To The Floor: How to repair sunroof on a Porsche 944 (Square Dash model)

[pfarah]

Thanks guys!

Sehrgut: I had the same issue and replaced the plastic dog, along with the newer cable, so they can be screwed on and not crimped. Also, the service manual states that 305mm is fully extended cable or closed, which is the method I used to align the arms to the cable. I'll look into adjusting the limit switches (perhaps a little further back...


Old Cable


Replacement Cable


Old Dog


Replacement Dog

[pfarah]

Latest update:

I moved the limit switches back as far as they would go along the rail and it actually started working!! Ok, for a little bit until the whole mechanism crapped out by always blowing the #9 fuse. After spending some time testing the system I discovered one of the motor brushes shattered and was ripped off the wire.



So, back to the drawing board... I spent this evening rebuilding the unit with spares and will reinstall tomorrow.






I also adjusted the lifting arms a bit lower so, hopefully, the roof panel should seat more flush with the roof line.