[whakiewes]

As I was redoing my headliner, I decided to tackle my sunroof as well. Its never really worked quite right... didn't tilt all the way (stripped drivers side gear), and if you held the lower switch in key position 1 to remove the roof, it would occasionally run all the way out. Solution was to not tilt, and just be careful when removing the roof. Well that didn't really work for me, so I took a look today. After reading Clarks garage with the upmost detail, I took everything apart via his instructions. My passenger side gears are perfect, but drivers side are stripped (the small gear, not big). The cable looks great, no real wear visible. But as I played with the limit switches, it appears I don't have a limit switch for the removal, I guess switch 1? Clarks garage makes it hard to understand, but when I lower the levers as to remove the roof, my motor never stops. I can literally completely remove the entire cable. Is this normal? It doesn't seem normal to me? I can't really find a 'fix' for that, and whenever I search I come up with nothing. Furthermore, as I was working, it appears that my two way switch on the center console decided to crap out. It lowers, but doesn't raise? Clarks garage said the check the upper micro switch, as it may be the cause, but it doesn't list great detail and my microswitch doesn't do crap. I can't figure out what he refers to when he says press the lever to hear a click...I can't find a lever.



Any help would be greatly appreciated as this is putting a hold on my headliner redo. I ordered two new sets of gears. Also my torque on my slip clutch was about 7-8nm. Really hard to tell exactly, but definantly high. I reckon' I might just pull the whole assembly apart and just rebuild everything?



Wes

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[apex]

Wes - when I replaced my sunroof gears I remember those damn instructions being very complicated! I had a devil of a time wrapping my head around how the mechanism functons. But eventually it became clear so stick with it.



I found a lot of help for my project on Clarke's garage, as you say, but I think the pelikan website tech section also has a useful write-up on sunroof diagnoses and repair. Also search on 968.net I believe you'll find posts from others who were in the same boat as you.



Most people recommend backing off on the slip-clutch torque a little bit to save gears. I didn't do take that advice and left well enough alone and haven't had any more trouble with gear-stripping two years down the road.



Would Clarke's Garage be referring to the "lever" on the microswitch? The little microswitches will click when depressed.

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[whakiewes]

Sunroof mechanism is fixed. Just took a ton of trial and error. About 3hrs, and I have it timed perfectly, two new gears, torque at ~5nm. Gears were $17 from my dealer, and they only had two in stock. I was only going to replace one, but one tooth on the other gear was worn a little so I replaced it as well. I am going to keep the other decent gear just in case, but will probably order some more.



Now on to the switch. This has me baffled, and for some reason im pretty sure its the microswitch that is located directly above the shifter under the sunroof latches. I have power going both ways on my switch, but no power making it to the motor to raise. I can't get to the wiring inbetween those areas easily. I just would like to understand what the mircoswitch is used for. All of my limit switches work now that everything is in time. It was just that the PO had them way out of wack. Sunroof lifts really nice now when I do it manually.



Wes

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[S_Cal968]

If I recall the microswitch above the shifter is for the alarm. If the panel was lifted the alarm would go off. I don't believe that switch is part of the actuation circuit.

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[968 Cab]

Hey guys - read the thread at http://www.968forums.com/index.php?showtop...563&#entry22563



I've done several Re & Re on those gears now and figured out the logic on the switches



good luck! back off the torque on the slip clutch as much as possible - I believe the plastic gears are meant to strip as a last resort.

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