I've done this twice now.
Here is the link to the Tech Article that I used as a reference.
http://www.pelicanparts.com/techarticles/9...944_sunroof.htm
It's a pretty good resource on the basic operation as well as the replacement of the gears.
One shortcut I've used is that rather than trying to get the headliner out of the weather stripping around the hatch, Ijust cut it to get to the gear assemblies after removing the cover piece. Once the cover piece goes back on, it covers the cut liner and holds it in place.
Pay careful attention to aligning the limit micro switches in the drive mechanism. I believe that misaligned micro switches are what cause the gears to strip. In other words, if the motor keeps driving the roof against the stops, a lot of torque is applied to the plastic gears. The slip clutch keeps them from failing right away, but if the switches work prperly, the motor stops before hitting the stops and the gears don't get stressed as much. I think this is why I had to replace them twice, but on the second time, I readjusted the limit switches and the gears have been good for 2+ years now.
Jamie
