Removal and installation of sunroof. 05 wagon

[jay.ritchie]

Hey guys,

Does anyone know of a sunroof specialist in Melbourne, close-ish to the templestowe/doncaster area?
I have a new sunroof to replace my screwed one and i need to get it installed.

Cheers

[jay.ritchie]

I've been quoted $700 by the Sunroof Specialist. The sunroof only cost me $300!

Does anyone think i could do it myself?
I've pulled the roof liner apart before to inspect the old one. Does anyone know if there's much involved in disconnecting and removing a sunroof?
And does anyone know how to re-seal them back up?

[jay.ritchie]

Does anyone have any experience with removing a sunroof from a gen 4 wagon?
I'm replacing mine and I'm curious as to how difficult it is. I've removed the roof trim before- but I'm not sure as to how the sunroof is sealed.

Any help will be greatly appreciated!

[dr20t]

Does anyone have any experience with removing a sunroof from a gen 4 wagon?
I'm replacing mine and I'm curious as to how difficult it is. I've removed the roof trim before- but I'm not sure as to how the sunroof is sealed.

Any help will be greatly appreciated!

I haven't done a wagon one but I can tell you a sedan one is a bitch.

I opted to chop the roof off halfway down the pillars with a reciprocator it was alot easier

Mick

[bigBADbenny]

Yes I removed the sunroof complete from Gambits wagon.
Big job but if you've had headliner out that's 1/2 the work...
The sunroof just drops out, the rubber seal around the edge is the only seal.

[jay.ritchie]

Yes I removed the sunroof complete from Gambits wagon.
Big job but if you've had headliner out that's 1/2 the work...
The sunroof just drops out, the rubber seal around the edge is the only seal.

Does the seal need to be replaced or can you sit it back on when the new one goes on?

[bigBADbenny]

Iirc the seal is the one around the edge of the s/r glass.

its attached to the glass pieces themselves.

the glass unbolts from the mechanism along with the glass leveling shims...

What is the reason for replacing the s/r?

I just sold the mechanism from Gambits wagon, but the buyer may just need a small spare part from it...

I still have the glass... Probably keeping the spare motor...

[jay.ritchie]

Iirc the seal is the one around the edge of the s/r glass.

its attached to the glass pieces themselves.

the glass unbolts from the mechanism along with the glass leveling shims...

What is the reason for replacing the s/r?

I just sold the mechanism from Gambits wagon, but the buyer may just need a small spare part from it...

I still have the glass... Probably keeping the spare motor...

Okay cheers, I thought that maybe the actual tracks where sealed to the roof too. That makes it easier anyway!
The sunroof had carked it. It started playing up about 6 months ago, the slider part that controls the front tilt panel broke. But i used a rolled up piece of paper wrapped in tape as a replacement part. This was good for a few weeks, when the old one wore out i would just make a new one! About a month ago it got jammed open. And when it eventually closed, the sliders snapped. Subaru and a sunroof specialist said the only way to fix any of the problems was to replace the rails. costing a few hundred and that would mean the whole thing would need to come out and get fixed. That was a big job in itself.

I eventually figured it would be a lot easier to buy a new one, so i wouldn't have to pull apart the broken one. (apparently pretty complicated). Found a used one in perfect condition and bargained it down to $320. Really stoked as wreckers sell them for $1550!!

Labor to get it replaced is $700. But as ive taken out the roof lining before, i figured i'd go a bit further and im sure i'll replace it fine myself.
Im 20, a student, and only make $320 a week. So i'm definitely keen on doing things myself before i pay someone $700.

[jay.ritchie]

When i get around to doing this ill post a walkthrough and pictures. Im sure someone will probably need some help one day.

[Ric]

I've just merged two topics that were essentially about the same sunroof

[bigBADbenny]

You'll DIY it for sure, just do it undercover, with plenty of light, time and someone extra on hand when you need help.
And the service manual : all relevant pages printed, bags for bolts & parts and a marker pen to label them.
Make sure your camera is charged as you'll want to document everything.
The mechanism is light without the glass installed.
The one key thing is not to operate the mechanism w/o glass or motor: the sliders can go out of sync irreversibly...

[jay.ritchie]

Yeah sweet.
I'm sure it'll go pretty smooth. I've got a mate helping me and I reckon we'll do it in the next few weeks!

[Ric]

Does that mean you will be driving an open top car on the cruise?

[jay.ritchie]

Does that mean you will be driving an open top car on the cruise?

I'd be buggered if it started raining! Nah i think ill make sure i get this done in one day!

[jay.ritchie]

Right! So i finally got around to replacing the sunroof yesterday.
You were right Bigbadbenny, not that difficult at all- Just extremely fiddly with all the components of the roof liner. Getting the liner back up was definitely the most time consuming part. I reckon it took me about 4 hours all together, including cleaning the new sunroof.

Taking the roof liner out, easy.
Taking the sunroof out, pretty easy. Theres about 16 bolts all the way around, and just two cables to connect it. There is two bolts on each side of the sunroof which are on brackets, so if you undo all of the bolts, the rails still sit on the brackets so you don't have to hold it. To remove the assembly i had to remove the two side brackets, so the rails would be able to drop, then i just slid it off the opposite side brackets, and out of the car.
With the glass off its pretty light, needed two people to lift it out though just because its big and awkward.

We put the new sunroof straight back in with the glass still attached, connected the cables, and did all the bolts up.
Then tested it and success!

The worst bit of it all was putting the lining back in. Theres so many little things that hold it up. Its really annoying. Especially when screws that hold the top of the pillars in fall down inside the car never to be seen again.

The lining was filthy from my fingerprints, so this morning i gave the entire interior a really good clean, including the lining.
I used Maguars Vinyl Cleaner for the first time for all the insides of the doors, and the front console area. It came up really nice, and now looks polished and protected.
Also took away the faded black look so its all jet black again. Still need to clean the front rails of the new sunroof, as i couldn't open the glass to clean the rails without it connected.


If anyone wants to know anything about removing and installing sunroofs, feel free to PM me as i think i now know it all!
Heres a link to an album of photos of the sunroof assembly if anyones interested.

https://www.dropbox.com/sh/ibypatsmaykuknx/7hPgrRsOQj


DRAINAGE:
Okay, i've come to the conclusion that the drainage system on the sunroof sucks.
As I'm studying architecture, and most people would also know this too, the sizes of drains and downpipes for buildings is calculated based on the area of the roof, and the location.
I believe the size of the drains on the sunroof isn't big enough to handle large amounts of water.
When the lining was off, i got the hose and tried to re-inact heavy rain. The drains can handle most of it, but with any excessive amount of water, it ends overflowing and piling into the car. The heaviest rainfall in Melbourne would most likely be too much for the drains, which i've experience with the old sunroof.
There's probably no way to fix this, other than siliconing the sunroof to the roof which i don't want to do.