So since last year November time frame, I've have a leak from my sunroof. After cleaning the drains, the rails, and everything possible, I was able to isolate the issue to a bad weatherstrip. I bought the replacement, but never had the time then since I was T-1 week to leave on my 7k mile road trip from CA to NY and back. I decided to seal the roof with a few good layers painters tape. It didn't look great, but it held up from December till now, in a wide range of weather. Snow, rain, sleet, hail, high winds, sand storms, -20 to 120 degrees. No issues. It's only that last week I had some time to address the problem.
Essentially, what seemed to be happening was once the roof was put into 'tilt' mode, putting in back in 'closed' mode made the strip catch and not close all the way from the rear center. Over time the repeated action of tilt/close/tilt/close started to pull the adhesive portion. This was where the leak was coming from. Since the weatherstrip also seemed to be deteriorating, I felt that it was time to get it all replaced. A call to a few SoCal d(st)ealership, and I decided to do it on my own. They were quoting from $1200-$2700, for replacing the seal!? WTH! Maybe they misunderstood what I was asking, but I was clearly asking for the weatherstrip to be replaced, ONLY.
Anyhow, I sourced the part for sub $50 from an online Toyota store (In Nov) and planned out last weekend to tackle the job. Overall, I think this job took me 3 hours of removal, cleanup, prep and an hour for two separate applications, 2 days to cure after each application to ensure it adhesion, 40 mins for cleaning up the mess and 20 mins to reinstall. Total 5 hours work time, not including cure time. I'm sure most can do it in under that time, but I'm pretty anal when it comes to these things, so spent time doing it the way I would be satisfied with it.
Lessons learned:
Parts needed:
Step 2: Taking off the seal and prep for new seal
Step 4: Clean up and installation
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Looks like I can only add 5 pics per post? lol. I'm just going to add a bunch of posts, if you have any questions, quote the pic and I'll try to answer to best of my ability.
Essentially, what seemed to be happening was once the roof was put into 'tilt' mode, putting in back in 'closed' mode made the strip catch and not close all the way from the rear center. Over time the repeated action of tilt/close/tilt/close started to pull the adhesive portion. This was where the leak was coming from. Since the weatherstrip also seemed to be deteriorating, I felt that it was time to get it all replaced. A call to a few SoCal d(st)ealership, and I decided to do it on my own. They were quoting from $1200-$2700, for replacing the seal!? WTH! Maybe they misunderstood what I was asking, but I was clearly asking for the weatherstrip to be replaced, ONLY.
Anyhow, I sourced the part for sub $50 from an online Toyota store (In Nov) and planned out last weekend to tackle the job. Overall, I think this job took me 3 hours of removal, cleanup, prep and an hour for two separate applications, 2 days to cure after each application to ensure it adhesion, 40 mins for cleaning up the mess and 20 mins to reinstall. Total 5 hours work time, not including cure time. I'm sure most can do it in under that time, but I'm pretty anal when it comes to these things, so spent time doing it the way I would be satisfied with it.
Lessons learned:
1. Know what you're getting yourself into before hand, LOL
2. Have all needed items on hand
3. Don't over tighten nuts
4. Helper would be nice
5. Don't make my mistake and remove the sunroof and bracket from rails, but just the sunroof and unbolt from bracket which is still attached to rails. I'll detail it out in pictures, but this part will save you the time in realignment of the sunroof so it sits flush with the roof
6. Don't over fill the weatherstrip groove with too much weatherstrip adhesive
2. Have all needed items on hand
3. Don't over tighten nuts
4. Helper would be nice
5. Don't make my mistake and remove the sunroof and bracket from rails, but just the sunroof and unbolt from bracket which is still attached to rails. I'll detail it out in pictures, but this part will save you the time in realignment of the sunroof so it sits flush with the roof
6. Don't over fill the weatherstrip groove with too much weatherstrip adhesive
Parts needed:
1. 63251-60062
2. Torx T25 + Phillips/cross-head
3. Racket (forget size)
4. Goo-gone, or something similar to take of old adhesive
5. Weatherstrip adhesive (3m or the like, I used Permatex)
6. Blade/pocket knife
7. Time & patience
8. Paper towels
Step 1: Removal of the Sunroof2. Torx T25 + Phillips/cross-head
3. Racket (forget size)
4. Goo-gone, or something similar to take of old adhesive
5. Weatherstrip adhesive (3m or the like, I used Permatex)
6. Blade/pocket knife
7. Time & patience
8. Paper towels
I had to take the painters tape off first, which was a PITA. Usually it never leaves any residue, but since I had it on there for a good while in all sorts of weather, it seemed to be baked on. Just made my life harder.
I have the T25 and Phillips shown in the photos, but I did *NOT* realize that I can remove the plastic covering around the sunroof and expose the 'golden nut' which would also take the sunroof off, but leave the rail-bracket on. Do that instead. Once I undid everything, I popped the sunroof up and forward a few inches so I can remove it from the outside. Make sure it doesn't slide down/fall, or you'll have bigger problems.
I have the T25 and Phillips shown in the photos, but I did *NOT* realize that I can remove the plastic covering around the sunroof and expose the 'golden nut' which would also take the sunroof off, but leave the rail-bracket on. Do that instead. Once I undid everything, I popped the sunroof up and forward a few inches so I can remove it from the outside. Make sure it doesn't slide down/fall, or you'll have bigger problems.
Step 2: Taking off the seal and prep for new seal
Pictured is the area where the weatherstrip was easily coming apart from the sunroof assembly. I guess in hindsight, my first step to remedy could have been just pumping it with the weatherstrip adhesive and letting it cure and putting it back on, however, that would have been a short term fix till issue resurfaced.
Pulling the seal off, I decided to cut it so it is easier to pull off. Noticed that there is metal in the OEM strip which keeps the structural integrity of the shape I guess. Obviously, I didn't cut the replacement to see, but since OEM, I'm guessing it has it too. Note: that there doesn't seem to be a lot of residue from the adhesive, meaning, a light amount on the new strip should be sufficient.
The weatherstrip seal also had to 'clips' on the front L & R sides to hold the hold in place. Make sure to loosen those so they are not damaged. These will help keep the strip in place when you put it back, so they cure in the correct position.
Initially, after liberally applying the goo-gone and letting it sit for a few minutes, I started to scrape off the old adhesive with a pocketknife wrapped with paper towels. However, since that was taking too long and required multiple passes of the knife, I decided to use the curved, yet dull portion from the back of the pocket knife.
It's also at this time that I accidentally popped off one of the sunroof black plastic molds which exposed the 'gold nut'. Had I seen this, installation (and removal!) would have been so much easier. I decided to take it off now, and go screw the bracket back into the rails, since it was going to be easier to screw in now. Alignment will be done once the sunroof was seated and screwed back in place.
Step 3: Application of adhesivePulling the seal off, I decided to cut it so it is easier to pull off. Noticed that there is metal in the OEM strip which keeps the structural integrity of the shape I guess. Obviously, I didn't cut the replacement to see, but since OEM, I'm guessing it has it too. Note: that there doesn't seem to be a lot of residue from the adhesive, meaning, a light amount on the new strip should be sufficient.
The weatherstrip seal also had to 'clips' on the front L & R sides to hold the hold in place. Make sure to loosen those so they are not damaged. These will help keep the strip in place when you put it back, so they cure in the correct position.
Initially, after liberally applying the goo-gone and letting it sit for a few minutes, I started to scrape off the old adhesive with a pocketknife wrapped with paper towels. However, since that was taking too long and required multiple passes of the knife, I decided to use the curved, yet dull portion from the back of the pocket knife.
It's also at this time that I accidentally popped off one of the sunroof black plastic molds which exposed the 'gold nut'. Had I seen this, installation (and removal!) would have been so much easier. I decided to take it off now, and go screw the bracket back into the rails, since it was going to be easier to screw in now. Alignment will be done once the sunroof was seated and screwed back in place.
I did a quick mock up with the new weatherstrip to see how installation plays out. I found out that I Had about 4 inches of extra length!? I couldn't figure it out... started to panic and wonder if I had purchased the right weatherstrip. Turns out I did, and the reason why I had extra was due to me pulling the strip as I installed it. I took it all off, and re-seated it without any pulling but just pushing down. Much better and it fit really snug and well.
The tube of weatherstrip adhesive I bought had a really wide mouth, so I decided to pinch it together with pliers so I could just push it into the groove and apply.
I split the adhesive job into half, and did one side only. Filled the weatherstrip, let it sit for a few minutes (per instructions from tube) and then proceeded to seat it on the sunroof and push it down completely. Immediately, I saw the weatherstrip start to slide back up in certain spots. I didn't get it... I thought it was due to me filling up the groove with too much adhesive, as it was also started to ooze out in certain areas. Oh well. I thought about taking it off, cleaning it up and starting again, but I wouldn't be able to clean the inside of the weatherstrip well, so decided to continue. Started doing the other side, filling it with less adhesive, but saw that it was doing the same. $%^& I thought.
Couldn't figure out what I was doing wrong, so I went back and started to apply a lot of pressure and hold on all of the areas that were coming up and started to hear popping sounds. Total sigh of relief... they were just air-pockets/bubbles. Went back and quickly, firmly and slowly applied constant HEAVY pressure on the seal and pop pop pop all of the weatherstrip started getting seated well and looked great. I then tightened the front weatherstrip guide 'clips' and let it cure for 2 days. I could have waited less but things always came up, life you know.
I came back and reapplied the adhesive to the area behind the groove but between the weatherstrip and sunroof as an additional bond/precaution. Didn't necessarily have to do this, but I felt like while I had it out, I would take care of it. This way, if the seal does come apart slowly overtime, the secondary seal would prevent from totally coming apart and letting water seep in between weatherstrip and sunroof. My logic at least. Water, regardless will still be able to enter, as it is designed to drain from the 4 drainage pipes in the corners of the sunroof assembly.
A few days later I did some spot checking to make sure no visible spots (from the second application) that had missed areas/bubbles that needed to be addressed. Nothing. Good to go!
The tube of weatherstrip adhesive I bought had a really wide mouth, so I decided to pinch it together with pliers so I could just push it into the groove and apply.
I split the adhesive job into half, and did one side only. Filled the weatherstrip, let it sit for a few minutes (per instructions from tube) and then proceeded to seat it on the sunroof and push it down completely. Immediately, I saw the weatherstrip start to slide back up in certain spots. I didn't get it... I thought it was due to me filling up the groove with too much adhesive, as it was also started to ooze out in certain areas. Oh well. I thought about taking it off, cleaning it up and starting again, but I wouldn't be able to clean the inside of the weatherstrip well, so decided to continue. Started doing the other side, filling it with less adhesive, but saw that it was doing the same. $%^& I thought.
Couldn't figure out what I was doing wrong, so I went back and started to apply a lot of pressure and hold on all of the areas that were coming up and started to hear popping sounds. Total sigh of relief... they were just air-pockets/bubbles. Went back and quickly, firmly and slowly applied constant HEAVY pressure on the seal and pop pop pop all of the weatherstrip started getting seated well and looked great. I then tightened the front weatherstrip guide 'clips' and let it cure for 2 days. I could have waited less but things always came up, life you know.
I came back and reapplied the adhesive to the area behind the groove but between the weatherstrip and sunroof as an additional bond/precaution. Didn't necessarily have to do this, but I felt like while I had it out, I would take care of it. This way, if the seal does come apart slowly overtime, the secondary seal would prevent from totally coming apart and letting water seep in between weatherstrip and sunroof. My logic at least. Water, regardless will still be able to enter, as it is designed to drain from the 4 drainage pipes in the corners of the sunroof assembly.
A few days later I did some spot checking to make sure no visible spots (from the second application) that had missed areas/bubbles that needed to be addressed. Nothing. Good to go!
Step 4: Clean up and installation
Re-enter Goo-gone. Applied liberally to the top portion of the sunroof, to clean it as well as remove all the additional adhesive which oozed out onto the 'wrong' (top) side of the sunroof.
Spent about 1 hour during this cleanup portion. During this time I saw that one of the corners I wasn't able to completely remove all the bubbles from or at least that I noticed. Due to this, it slid up a little. Kinda annoyed myself that I didn't notice it sooner and address it. Oh well. It would have been hard to notice anyway, since installation is happening on the underside of the sunroof, and it needs to stay that way for it to cure properly. Otherwise the sides would get additional pressure due to the curved glass of sitting right side up and possibly unseat the center parts of the seal.
Cleaned up, the 'mistake' of one sides sliding up (when right side up, it would look to be sliding down) didn't seem too bad! All perspective I guess. However, everything else seemed to be seated perfectly, or to my liking!
Finally, the time came to re-install the sunroof, and while it was a piece of cake. Re-aligning was a PITA. Furthermore, it was about 1am, and I was going out wheeling the next morning. In that excitement... I over-tightened one of the 'gold nuts' and it snapped right off. %^&*. Really!? I come all this way and make a rookie mistake? Well $h!t. Nothing I can do now. Roof is aligned. Seated well. Opens and closes fine. It also barely moves if I try to push it up (this was also stupid, I shouldn't have done that - in case something else happened). I haven't decide how I will replace that nut just for peace of mind. Maybe have a friend just weld that area? Not sure. I don't have welding skills so will pass for now.
Real test will be tomorrow when I test with some water... if that passes then will take a hose to it. If that passes will take it to the car wash for a torture test. So far, its passed the first two tests really well so will take it to the car wash sometime soon! Didn't see a drop coming into car, other than the standard water going between the weatherstrip and body and heading to the drains! Good deal, and all for sub $100!
Hope this helps any of you interested, or thinking about replacing your sunroof weatherstrip seal. Definitely doable, however, learn from my mistakes.
Spent about 1 hour during this cleanup portion. During this time I saw that one of the corners I wasn't able to completely remove all the bubbles from or at least that I noticed. Due to this, it slid up a little. Kinda annoyed myself that I didn't notice it sooner and address it. Oh well. It would have been hard to notice anyway, since installation is happening on the underside of the sunroof, and it needs to stay that way for it to cure properly. Otherwise the sides would get additional pressure due to the curved glass of sitting right side up and possibly unseat the center parts of the seal.
Cleaned up, the 'mistake' of one sides sliding up (when right side up, it would look to be sliding down) didn't seem too bad! All perspective I guess. However, everything else seemed to be seated perfectly, or to my liking!
Finally, the time came to re-install the sunroof, and while it was a piece of cake. Re-aligning was a PITA. Furthermore, it was about 1am, and I was going out wheeling the next morning. In that excitement... I over-tightened one of the 'gold nuts' and it snapped right off. %^&*. Really!? I come all this way and make a rookie mistake? Well $h!t. Nothing I can do now. Roof is aligned. Seated well. Opens and closes fine. It also barely moves if I try to push it up (this was also stupid, I shouldn't have done that - in case something else happened). I haven't decide how I will replace that nut just for peace of mind. Maybe have a friend just weld that area? Not sure. I don't have welding skills so will pass for now.
Real test will be tomorrow when I test with some water... if that passes then will take a hose to it. If that passes will take it to the car wash for a torture test. So far, its passed the first two tests really well so will take it to the car wash sometime soon! Didn't see a drop coming into car, other than the standard water going between the weatherstrip and body and heading to the drains! Good deal, and all for sub $100!
Hope this helps any of you interested, or thinking about replacing your sunroof weatherstrip seal. Definitely doable, however, learn from my mistakes.
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Looks like I can only add 5 pics per post? lol. I'm just going to add a bunch of posts, if you have any questions, quote the pic and I'll try to answer to best of my ability.
