Sunroof rust issue. Thoughts on how to repair? (1 Viewer)

[Red Merle]

These sunroofs are delivered to Toyota as a unit, with the seal permanently installed. Unlike the 100s and 200s, which have $30 replacement seals, you have no option other than to buy the replacement glass. Yes, for $400, if you can find them for that.

You and I know what the problem is; someone with a later model can't appreciate what a PITA the glued on fabric is. The glass is the only sealed component you have to worry about. Everything else you can take care of when you swap the glass. The pan seal is another story; I don't see how that would be easy to get at. I think you can get the glass out of the early models without mangling the headliner fabric, but not the pan. Someone who's done it before would be a better resource than me. @cruiserdan probably knows.

I agree I'd stay away from used glass, even if it's "verified" leakfree, when it was removed. The seal's 20+ years old. Read my earlier posts on the sunroof drain subject; @MoJ, post #10, is correct, the dust seal on the glass does tend to regulate the ingress of water, but it doesn't seal it out at all. The drains were intended to carry the water away from the interior. If you've a rust problem, I doubt it's a clogged drain tube, although it's not impossible. More than likely it's a dirty rocker panel void. The pinch drains get plugged and the water backs up, into the floorboard and the sunroof tray/pan/frame (whatever we're calling that these days; Mr. T calls it the housing assy)

Thanks for the feedback. I may regret ordering this used one, but if it works, I saved 300 bucks and if it doesn't, I wasted $100.

As for how this got rusty to begin with, I am at a loss to diagnose it because I haven't had any leaking symptoms in the 18 months I have had the truck. If I end up having to order a new unit, so be it, but I just had to buy a new fridge on Friday for my house and I am a little tapped out at the moment.

I am starting to see why so many people hate these sunroofs.

 

[Tools R Us]

... Ospho ...

... Rust Mort ...

Both phosphoric acid based products, good stuff, but those brands are about the most most expensive way to buy it.

Klean-Strip 1 gal. Phosphoric Prep and Etch-GKPA30220 - The Home Depot

 

[Malleus]

Thanks for the response. I agree that removing the sunroof is not really an option. As for the ospho, I wasn't really disagreeing with you, I just thought he had it down to bare metal and that not using it probably wouldn't have caused problems for him. That said, this is an entirely different situation and I know for sure I am not going to be able to get this really clean without damaging the seal. I have some Rust Mort Rust Mort™ | morttm | SEM Products. Do you think that will be OK?

What are your thoughts on the caulk vs. body filler idea? I could shoot some caulk in there and let it cure and then use the body filler. That way there would be a little flexible layer to account for expansion. I feel like I need to do something though or I might run into trouble with the metal frame becoming unstable.

I've never used RustMort, so I can't say. @Tools R Us is right, Ospho really likes their stuff. Zirconium phosphate is even more expensive. I wouldn't use caulking personally.

 

[Malleus]

Thanks for the feedback. I may regret ordering this used one, but if it works, I saved 300 bucks and if it doesn't, I wasted $100.

As for how this got rusty to begin with, I am at a loss to diagnose it because I haven't had any leaking symptoms in the 18 months I have had the truck. If I end up having to order a new unit, so be it, but I just had to buy a new fridge on Friday for my house and I am a little tapped out at the moment.

I am starting to see why so many people hate these sunroofs.

People hate their juvenile deliquent kids too. Everything needs care and feeding to live long and prosper...

 

[Red Merle]

People hate their juvenile deliquent kids too. Everything needs care and feeding to live long and prosper...

Well, you talked me into trying to cancel the order on the used one. The one that is in the truck now still seals(at least I think it does) I am just going to hold of for now and wait to collect another couple of paychecks and order a new one. I might see if I can get the old one out and do a repair in the meantime, just to see.

 

[Malleus]

On the subject of finding something you weren't looking for, read the TSB and browse the catalog. Again, not directly related to the current topic but, if Mr. T thought enough of this stuff to recommend it, I'm stocking up.

 

[Malleus]

Well, you talked me into trying to cancel the order on the used one. The one that is in the truck now still seals(at least I think it does) I am just going to hold of for now and wait to collect another couple of paychecks and order a new one. I might see if I can get the old one out and do a repair in the meantime, just to see.

Let me know how it goes. If I can offer any long distance support, you know where I am...

 

[MikeB]

You can improve the sealing of a worn dust seal by sliding some thin material under it to shim it out. There have been threads about doing this with strips of bicycle inner tube, and also with speaker wire. But your rusty frame might not be straight and solid enough for that to help.

 

[1973Guppie]

what about just welding it all up? seems to me alot of work for something that I really don't use very often. I know if mine went south I would just weld in a panel to delete the whole thing. I guess it depends on if you really want / need a sunroof.

 

[White Stripe]

Racer65 on here could probably make new seals for the sunroof. A decent seal would have to be sent to him so he could duplicate it. He has been making nla seals for 40s and 60s on his website.

 

[Red Merle]

what about just welding it all up? seems to me alot of work for something that I really don't use very often. I know if mine went south I would just weld in a panel to delete the whole thing. I guess it depends on if you really want / need a sunroof.

I thought about that, but I actually use mine quite a bit because I leave it open if my dog is in the truck and I have to leave him in the truck when it's warm out. Besides, I don't have a welder and hiring someone to do this job and do the paint work, etc, would probably cost more than a brand new glass/seal assembly. Good thought though

 

[Red Merle]

Racer65 on here could probably make new seals for the sunroof. A decent seal would have to be sent to him so he could duplicate it. He has been making nla seals for 40s and 60s on his website.

Interesting. I may look into that if all else fails. Thanks for the tip!

 

[Malleus]

Paging @Racer65

 

[Red Merle]

Welp, the eBay seller didn't even bother to respond to my request to cancel the order. He just went ahead and shipped it out, poste haste. I guess it's mine now.

I could see in the pics that some of the little "strings" of weatherstripping on the edges were peeling back a few inches, but I am pretty sure mine has that problem too. The bulk of the weatherstripping looked decent in the pics though. Suppose I wanted to try to glue those little pieces back on there, what would be a good product for such a thing? I have some Toyota FIPG in black left over from my head gasket project. Would that work or should I be thinking more of a glue?

 

[White Stripe]

I would really try to get ahold of racer65, if he can make new reproduction ones then you can use those.

 

[Red Merle]

I would really try to get ahold of racer65, if he can make new reproduction ones then you can use those.

Any ballpark idea what something like that would go for? It seems like kind of an advanced gasket with the little fuzzy parts on the sides, mated to the rubber seal that you see on the roof. Keep in mind I can get a brand new unit from McGeorge for $400, shipped.

Here is the listing for what could very well be someone else's garbage that I bought. The price was right and the part that is rusted on mine looks fine. The weatherstripping looks suspect though. Even if it only lasted a few months, I could get this project into my budget behind the AC work and the gas tank project that I already have scheduled. Alternatively, I could just jam the used one back on eBay and do nothing until I can afford a whole new unit from Mr. T. Fingers crossed this part doesn't end up on beno's kill list. It seems like the same part for all years though and I gotta imagine more than a few of these get busted every year.

1993 TOYOTA LAND CRUISER SUNROOF SUN MOON ROOF MOONROOF GLASS TINTED TINT OEM | eBay

 

[White Stripe]

I have no idea man. New one may be worth it.

 

[Red Merle]

I have no idea man. New one may be worth it.

No sweat. I have had people make me parts that were NLA from Toyota, but it ended up being more than twice as expensive as what the original unit would have been. I have no qualms about the fact that I paid what I did for that part and it was done very well, but if I can get the real McCoy for around the same price, I would rather just go that route.

I am very curious to know how he makes these though. It seems like something that would need some very specific equipment. Does he extrude them or something or use a mold or does he fashion the gaskets out of something he tools down to the proper shapes?

 

[White Stripe]

No sweat. I have had people make me parts that were NLA from Toyota, but it ended up being more than twice as expensive as what the original unit would have been. I have no qualms about the fact that I paid what I did for that part and it was done very well, but if I can get the real McCoy for around the same price, I would rather just go that route.

I am very curious to know how he makes these though. It seems like something that would need some very specific equipment. Does he extrude them or something or use a mold or does he fashion the gaskets out of something he tools down to the proper shapes?

I think he has a company he knows do it for him.

 

[Red Merle]

I received the used sunroof today and installed it. The seal was in great shape and the whole process was really painless. I didn't even snap any of the trim clips. Looks like one finally went my way


I will say that if I would have followed the FSM, I would have been into the headliner and for this job, it wasn't necessary at all.