Sunroof Stuck

[ElDoCrzr]

I've searched the archives and can't seem to find a fix the sunroof problem on my 97. The driver side rear corner of the sunroof no longer moves upward to seal shut nor does it is lift when I tilt the sunroof. Otherwise the sunroof opens and closes fine.

The sunroof also has to work very hard to close when the engine is not running. Not sure if this is related.

I'm trying to avoid having to pull the liner, but need to get this fixed before it starts raining here in NoCal.

Anybody else had this issue?

[Blue Bomber]

I am having the exact same problem. I have posted twice for help, and done a lot of searches.

The problem is that it becomes detached from the cable. You can (carefully) pull the trim pieces, then unbolt & remove the glass panel to see the mechanism, when in the closed position. If you find a fix, please PM and post. I have disconnected the switch and wedged it flush. I really miss the sun roof.

[MyCrush]

I am also have those exact symptoms.....Took it to a local dealer to diagnose and they came back w/ the cable on DS has broken free and needs replacement. All this for the mere pittance of 1200.00 bux.
There has to be a more prudent fix.

[Blue Bomber]

Does your cable still move?

Does anyone know how the carrier attaches to the cable? That appears to be the problem.

[MyCrush]

< bump >

[1shot1kill]

Someone will chime in, hang in there! Mine leaks and living in Oregon means tape time for another 6 months!

[breadbox]

Mine shuts and seals fine but when it rains it sometimes leaks on the passenger side front and back? I am going to have my dad take a look at it and see what he thinks, he is a body and fender guy and pretty handy with fixing stuff. I will let you know how it goes and I will also ask him about the cable too.

[ElDoCrzr]

On the driver side the cable is jammed and not moving on its own. The passenger side moves the sunroof forward and back via the cross member, but can't raise the driver side back into position to seal it or tilt it up.

The dealer wants almost $800 just for parts: 2 rails, the cross member and cables. They say that both rails should be replaced as PM on the passenger side.

Work includes dropping the headliner. If they do the work they want another $1k!

This blows...

[uberhahn]

I work for a sunroof company. Not the one in question here though. So here are a few known possible problems for the symptoms you're having:

if the cable becomes detached from the mechanism, the cable needs replacing (at least with the units i'm familiar with). Usually, there is an overmolded coupling at the end of the cable that connects to the mechanism.

In order to R&R the cables, typically, the full module needs to be removed. In fact, removing the module is easier than removing and replacing the headliner.

Typical prices of material only for replacement is about $500. Labor is about $600.

My suggestion is to try to find one at a salvage yard. Otherwise, try lubing the tracks. You can also try to remove the motor, then move the cables independently.

Good luck.

[Blue Bomber]

Ok, so I had some time this afternoon and took another look at this one. I have identified the problem, now just to fix the problem...somehow. Any idea?

1. First, remove trim (carefully, as one of mine blew up, other removed more carefully) and glass. Tilt up sunroof.
2. Remove two screws highlighted in picture. Be very careful, as they are threadlocked and not much to push against.
3. Detach outer metal piece, being very careful not to lose the two plastic pieces that ride in the grooves in the metal pieces.
4. You can now rotate the piece to the front of the vehicle, and expose the broken piece that is attached to the cable. Shown in the other picture.

Any ideas as to a fix??? I do not see a way to easily fix, without total removal of the whole system.

[voorland80]

I have a complete sunroof assembly from a '93. It's in closed position. Without hooking up power to it, I can't get a better look. I can't quite figure out the bottom photo. But if there's a part you need that I can get to, I'm willing to help.

[lagwagon]

I have 2 or 3 sunroof assemblies and if you want to check them out I am not too far.
Jeff in Davis, Ca 530-219-5801

[breadbox]

Do the drains for the back of the sunroof come out in the rear wheel wells? I can see some drain holes, just want to make sure before I try and unclog it.

[Blue Bomber]

Thanks Jeff. I might take you up on that if I can get a planned day off.

Here is a clarified version of the picture. The front portion is attached to the cable. The sun roof will open, but will not close or tilt up at all since nothing is pulling it forward.

[MyCrush]

Since it will be full-blown winter here soon, I wonder if anyone sees a way to just seal it back in it's most forward position, and just wait 'till the next thaw'.
Any thoughts?

[strong_toy]

I'm also having similar problems with my sunroof. I have only removed the glass and can see the cable move on each side, but I think they may both be disconnected. The sunroof seems to open fully but will not close completely (won't tilt up to seal in the back). There is lag when opening and closing which leads me to think that the slide is disconnected from the cable. One other note is that I have to use a combination of open & down to open the sunroof and close & up to close it.

Blue Bomber, do you have similar open/close lag with your broken cable(s)? Also, do you have to use the same switch combos to open/close?

If I need to drop the headliner to replace the cables or tracks, then I will wait until I can remove a sunroof unit from a wreck. Plus while the headliner is down I might weld up the roof rack holes.

[Blue Bomber]

On the driver's side, the cable does not pull the glass forward or up. It will still retract. Closing or tilting up is just the other side doing the work, putting strain on everything. See pic in #14 for your probable problem.

[strong_toy]

Originally Posted by Blue Bomber

On the driver's side, the cable does not pull the glass forward or up. It will still retract. Closing or tilting up is just the other side doing the work, putting strain on everything.

Have you made any progress on repair?

I'll try removing the sliding rails from the tracks tomorrow to see if the cables are detached as you show. It seems odd that mine both broke at the same time. The sunroof was fine until this failure and it has been used almost every day.

[voorland80]

That does it.
I'm keeping the spare sunroof assembly should the sunroof in my 80 someday take a dump.

[BrotherRob]

Same issue here. Its a detached and/or broken cable. My understanding is that it cannot be repaired without removing the entire unit. I had the glass out a year ago and was able to manually tilt the glass up to the proper closed position. Sorry, I don't remember how to do it but it is possible.

The FSM and the factory parts manual have little information. Judging on the information on MUD or lack thereof, very few have removed the sunroof and serviced it. I think we are all going to have to take the exploration method and figure it out as we go.

[ElDoCrzr]

A local sunroof installer (Sac Valley Sunroofs) confirmed what the dealer told me about my sunroof - the cable is broken on the driver side rail. The only fix is replacing the entire mechanism which involves dropping the headliner.

The rails sell for about $375 each (and the suggestion is to replace both as PM since taking the headliner down is such a pain). Apparently there is not a big supply of rails around so expect a delay in getting parts.

The sunroof dealer estimated it would take him 8-10 hours of labor.

[BrotherRob]

I've pulled a headliner in an 80 once. PITA but can be done with basic hand tools. If you have a safe place to store it, I would pull the headliner before going to the shop. It would save you 4 to 5 hours of labor and also give you the chance to clean it while it is out.

[strong_toy]

I have not had the time yet to pull the glass back out, remove the slide/tilt parts, and look at the cable connections. I have looked online at salvage yards and sunroof assemblies are relatively easy to find. I found one local and will try to look at it tomorrow and have it removed. FYI, the price is in the $100-300 range depending on the salvage yard so this seems a much cheaper option than buying new rails from Toyota at $300/each (plus you get everything but the motor).

[strong_toy]

After posting I decided to look at the sunroof again tonight. I removed the glass and pushed the tilt mechanism forward on each side with a screwdriver. After doing this I could see the cable attachment point that Blue Bomber illustrated. It is broken and looks just like the picture in post #14. Therefore, it is not necessary to follow steps 2 & 3 in post #10 to verify that the cable connection is broken.

Now, I will definitely go buy a salvage sunroof assembly to replace the rails.

One note, I realized by moving the tilt mechanism with the screwdriver that it can be manually positioned (tilted) so the sunroof will seal properly along the back edge without using shims, etc. All that is needed is to move the bushing (shown in post #10) into about the middle of the slot.

I'll update in a day or two after finding a used sunroof assembly. Looks like the next step is to remove the headliner which seems like a good weekend project...

[MyCrush]

Good work ......thanks for that info !

[strong_toy]

I bought a used sunroof assembly today. Here is a pic with the glass removed. I'll probably start removing the headliner by the weekend. Since the headliner is coming out I'm considering filling the rack holes in the roof and adding a rear interior light behind the 3rd row seats. I might even do something with the speakers. Any other thoughts on what to do while the headliner is out?

[Tapage]

can you take a pic of the piece on your new ( for you ) sunroof asembly .. ?

[strong_toy]

Originally Posted by Tapage

can you take a pic of the piece on your new ( for you ) sunroof asembly .. ?

Do you mean the cable attachment point? If so, I can shoot and post it in the morning.

[Tapage]

Originally Posted by strong_toy

Do you mean the cable attachment point? If so, I can shoot and post it in the morning.

yes .. thanks !

[strong_toy]

Tapage, here are a couple of close-up pics of the cable connection (one side) on my salvage sunroof. I have been delayed in posting because I dropped the headliner Thursday night.

Removing the headliner takes about 2 hours and then I spent another hour re-attaching the door trim and seatbelts and organizing screws so I can use the truck while the sunroof is being replaced.