Sun Roof repair - Printable Version

Sun Roof repair - Printable Version

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Sun Roof repair - rhudeboye - 06-28-2009

My gears are fine, They show no damage. My sunroof would only lift about an .5" I've just located the motor in the hatch but I dont see the adjusting bolts/ screws to change the torque. Could someone tell me what I should be looking for?

Also, should the gears move even though the roof and lifting arms are removed? Once I removed everything, I can no longer get it to respond.

Sun Roof repair - PorscheDude - 06-28-2009

I think you have to remove the motor from the body, the adjustment is on the far side.

Also check the limit switch. It could be switching off power to the motor too soon.

Sun Roof repair - rhudeboye - 06-28-2009

QUOTE (PorscheDude @ Jun 28 2009, 04:33 PM) <{POST_SNAPBACK}>I think you have to remove the motor from the body, the adjustment is on the far side.

not according to clarks write up. But you maybe correct as I dont see a torque adjustment.

"Also check the limit switch. It could be switching off power to the motor too soon."
Agreed, I just cant make sense of how to adjust it. Dont even see any adjustment parts.

Sun Roof repair - rhudeboye - 06-28-2009

As it turns out. My cable had to be reset and the tab in the front of the sunroof between the visors wasnt being contacted. No parts were needed to get my roof working all this time. Just adjustments.

Sun Roof repair - S_Cal968 - 06-28-2009

Yep, sounds like an indexing issue. There's not a lot of adjustment with the micro-switches. The problem I had is the drive cable would back out of the drive unit and that fricked-up any attempt at indexing.
With the arms out, electrically set the cable/drive unit to full open, [the arms have to be on the same tooth]. Retract the arms [carefully] to the full closed and check that they extend equally out of the gearbox. Actuate out and back in again to verify indexing. Then slowly retract the arms into the park position for panel install.

~~~~~~~~~~
oh, glad it was an easy fix.... thx for the update....

Sun Roof repair - Lim Yong - 06-29-2009

more info please, mine does not open at all, drive cable backed out like yours? how did you get the cable/motor to go so the arms will lift the roof? thanks

Sun Roof repair - rhudeboye - 06-29-2009

QUOTE (S_Cal968 @ Jun 28 2009, 07:31 PM) <{POST_SNAPBACK}>Yep, sounds like an indexing issue. There's not a lot of adjustment with the micro-switches. The problem I had is the drive cable would back out of the drive unit and that fricked-up any attempt at indexing.
With the arms out, electrically set the cable/drive unit to full open, [the arms have to be on the same tooth]. Retract the arms [carefully] to the full closed and check that they extend equally out of the gearbox. Actuate out and back in again to verify indexing. Then slowly retract the arms into the park position for panel install.

~~~~~~~~~~
oh, glad it was an easy fix.... thx for the update....

Wish I read this 1st. Thats exactly what I had to do. Problem is, I'm not sure I extended the cable all the way across. Once I threaded it through, I put the lifting arms back in place then cranked them all the down manually from the bolt on the motor. Should I revisit that to ensure that the gear doesnt break?

I also have no idea as to how much torque I added by twisting that little bolt near the motor (bolt #2). Thats the most poorly thought out adjustment i have ever seen.

Sun Roof repair - S_Cal968 - 06-30-2009

@Lim; it's just a matter of indexing. Once set it works fine. I'd suggest removing the cover over the drive unit to see if the drive cable is in the correct position. The drive cable is [in theory] held in position by a guide arm. Also, check that the worm drive is visible when you have the right-side [passenger side], gearbox apart. This may seem confusing, but once you see the drive assembly this will all make sense. If the cable is protruding past the guide arm, it can easily be re-positioned, if the lift arms have been removed.
BEFORE TESTING, be sure to remove the lift arms. If 1 arm isn't indexed correctly the drive will strip the gear, [ask me how I know]. Or you can try your luck and carefully actuate the drive, [bump the switch].

@Rhudeboye; I don't typically use the manual method unless it's absolutely necessary. When I indexed the arms I just bump the switch and watched closely. Since it's a PITA to replace the gears, I'd suggest double checking the indexing, [measure the extension of the arms or count the teeth protruding].

BTW, use a non-migrating/mild grease [that won't attack the gears] when assembling the gearbox.

Sun Roof repair - rhudeboye - 06-30-2009

QUOTE (S_Cal968 @ Jun 29 2009, 10:04 PM) <{POST_SNAPBACK}>This may seem confusing, but once you see the drive assembly this will all make sense.

@Rhudeboye; I don't typically use the manual method unless it's absolutely necessary. When I indexed the arms I just bump the switch and watched closely. Since it's a PITA to replace the gears, I'd suggest double checking the indexing, [measure the extension of the arms or count the teeth protruding].

True, it all makes sense to me as I was in there for over 2 hours Sunday. however before looking at it I wouldn't be able to follow you.

I counted teeth. What I wasn't sure about was how far I should have advanced the cable. I was using the switch with the roof removed and it would only reverse the gear. I held it too long and the cable completely left the passenger side. I tried to fwd the gear but it wouldnt go (later I found out it was do to my front sensor switch). So I was left with the manual crank until I could see the cable reappear. Once it did I let it travel completely across, about another 4 cranks, then I positioned my arms.

Was I suppose to crank until the cable stopped then position the arms?

Sun Roof repair - wmuldowney - 06-30-2009

Great post, I too am having trouble with the sun roof. passengers side gear wasted and the contact at front of sun roof not adjusted . Mine stays open and wont close all the way, guessing that is not synchronized properly as well. Read all of the above posts and will get into it more this afternoon

Sun Roof repair - S_Cal968 - 07-01-2009

QUOTE Was I suppose to crank until the cable stopped then position the arms?
Well this is another reason why I position the cable electrically. When the drive unit gets to the micro-switch and the motor stops, that's when you install/index the arms.
Sorry this is confusing, unfortunately I didn't take any pics the last time I had everything open...
HTH

Sun Roof repair - wmuldowney - 07-01-2009

QUOTE (S_Cal968 @ Jun 30 2009, 09:13 PM) <{POST_SNAPBACK}>Well this is another reason why I position the cable electrically. When the drive unit gets to the micro-switch and the motor stops, that's when you install/index the arms.
Sorry this is confusing, unfortunately I didn't take any pics the last time I had everything open...
HTH

Now you tell me! But hey after the 3rd/4th or 5th try I got it! LOL
I look at it this way, next time, cause there will be a next time, I'll know what I doing.

Sun Roof repair - rhudeboye - 07-01-2009

QUOTE (S_Cal968 @ Jun 30 2009, 11:13 PM) <{POST_SNAPBACK}>Well this is another reason why I position the cable electrically. When the drive unit gets to the micro-switch and the motor stops, that's when you install/index the arms.
Sorry this is confusing, unfortunately I didn't take any pics the last time I had everything open...
HTH

My wire wouldnt extend electronically, it would only retract. I'm going to go at it again over the weekend. Going back in will be much faster now that I know where everthing is and how it all pulls apart.

Thanx

BTW - stop saying your confusing! Your posts are very well written.

Sun Roof repair - wmuldowney - 07-04-2009

I am having trouble with the senser/contact/micro switch at the front of the sunroof not making contact. Is there any adjustment proceedure for that? I have looked thru the posts but didnt seem to locate that specific item.

Sun Roof repair - S_Cal968 - 07-04-2009

The m/switch is one of those things that works or doesn't work, there's no adjustment. Is it possible to tape it into position while servicing?

Sun Roof repair - wmuldowney - 07-04-2009

QUOTE (S_Cal968 @ Jul 4 2009, 07:32 AM) <{POST_SNAPBACK}>The m/switch is one of those things that works or doesn't work, there's no adjustment. Is it possible to tape it into position while servicing?

Its intact and works, when sun roof is installed, I must push on the metal triangle to engage mechenism properly. I guess I could put something on the contact that will "close the gap"?

Sun Roof repair - PorscheG96 - 02-07-2010

Actually there is an adjustment for the sunroof micro-switch but it's on the sunroof, not on the micro-switch itself. If you're sitting in the 968 and look up at the underside of your sunroof, you'll see some buttons in the form of a triangle just inches apart from each other filling 3 holes at the front of your sunroof. Removing the rear 2 buttons will uncover allen screws used for the micro-switch adjustment. Backing out these allen screws slightly will increase pressure exerted by the front metal tab of your sunroof on the micro-switch which allows your sunroof to open higher. You should adjust each allen screw equally, in other words don't just loosed/tighten one of them, and I recommend doing incremental 1/2 turn adjustments between each sunroof raising attempt until it opens fully 2-3". This adjustment should always be checked first before making other, more challenging diagnosis for sunroof issues. You should only have to mess with the motor/clutch assemblies if the motors are burned out or you stripped the gears due to excessive clutch tension.

Now if I can just figure out why my sunroof has some play between it and the arms when raised...

Sun Roof repair - rhudeboye - 02-07-2010

I know exactly what your describing. I had no idea it did that. I'm gonna give it a try. I would like to get another half an inch

Sun Roof repair - Cloud9...68 - 02-07-2010

"Actually there is an adjustment for the sunroof micro-switch but it's on the sunroof, not on the micro-switch itself. If you're sitting in the 968 and look up at the underside of your sunroof, you'll see some buttons in the form of a triangle just inches apart from each other filling 3 holes at the front of your sunroof. Removing the rear 2 buttons will uncover allen screws used for the micro-switch adjustment. Backing out these allen screws slightly will increase pressure exerted by the front metal tab of your sunroof on the micro-switch which allows your sunroof to open higher. You should adjust each allen screw equally, in other words don't just loosed/tighten one of them, and I recommend doing incremental 1/2 turn adjustments between each sunroof raising attempt until it opens fully 2-3". This adjustment should always be checked first before making other, more challenging diagnosis for sunroof issues. You should only have to mess with the motor/clutch assemblies if the motors are burned out or you stripped the gears due to excessive clutch tension."

PorscheG96:

I nominate your above post for post of the year! Thank you so much for actually explaining how to adjust these mythical microswitches. I've been fumbling around the switches themselves, all befuddled and confused, trying to figure out what possible adjustment device exists on these odd-looking switches.

PorscheG96's post should be a model for all of us to follow; I'm sure I've been guilty of this myself, but it's very frustrating for those of us struggling with a problem in an area of the car we're unfamiliar with, to read through a series of posts describing what appears to be something related to our problem, but without explanations of exactly what's being described, where the thing that's being described is located, without any pictures to help identify what we're supposed to be fixing, and above all, how to actually go about fixing it, step by step. In other words, a statement like "I would try adjusting your microswitches" is of no use whatsoever to those of us who've never worked on our sunroofs before.

OK, I'm down from my soap box now. In my car's particular case, I can't get the sunroof to lock. I follow the instructions given on page 53 of the owners manual, but the motor doesn't drive the sunroof into the down position when I despress the switch on the console as described in the manual. It works in the other direction (to unlock the sunroof so I can remove it). I have to use a socket (I think it's an odd size, like 21 mm or something) to turn the screw on the motor back in the left wheelwell to lock my sunroof into place. I'll start with ProscheG96's description of how to adjust the microswitches. If this doesn't work, what should I try next? Thanks.

And I apologize if my criticism of earlier posts in this thread comes across as too harsh. It's just that seeing a post as well-written as PorscheG96's makes me think that if someone with the knowledge of how to adjust the microswitches had written something similar way back when this thread started, it would have saved me (and probably several others) a lot of frustration, and I might have a working sunroof by now, instead of punting and just leaving it off all the time, which has left me stuck in a couple of surprise rain storms with no sunroof.

Sun Roof repair - rhudeboye - 02-07-2010

Not sure too many knew about this. Actually, has it even been validated yet?

I got the best help from Clarks garage. I started with the symptoms section and discovered that my problem was the tab that slides into meet the micro switches. I'm guessing your problem is there to. However I don't recall Clarks otherwise well written DIY including the adjustable screws mentioned by G96.
But it does make sense. Turning the screws simply angles the metal tab. In turn the metal tab pushes further toward the micro switch tripping the switch.