Servicing Sunroof Mechanisms

NOTE: The numbered call-outs in the following service procedure refer the numbered parts found in the exploded view diagram.

Individual mechanism parts are available. The following procedure pertains to complete mechanism and/or cable replacement. Some steps may not apply to the particular component that is being replaced. Read through the entire procedure before proceeding, to determine which steps do apply when replacing parts, it is not necessary to disassemble the existing mechanism component assemblies. Use these assembled components for reference when installing new parts.

REMOVAL
1. Operate sunroof glass panel (1) to the vent position.
2. Remove sunroof module (10), separate from vehicle, and place on a clean work bench.
3. Remove sunshade (6).
4. Remove glass panel (1).
5. Remove screws (42) and washers (41) from glass panel supports (3) on both sides.
6. Remove glass panel supports (3) and glass panel tracks (27) from both sides.
7. Remove drive motor (21).
8. Remove screws (38) holding sliding roof panel cam block (37) to housing track 10..
9. Disengage glass lift arm (35) from actuating link (34). Separate sliding roof panel cam block (37) from sunroof module track.
10. Drill rivets and remove water trough (45).
11. Remove panel down stops (47).
12. Slide actuating link (34) to track opening and remove actuating link (34).
13. Note position of cable in panel front guide (28) and pull the panel front guide (28) out of the rear end of the housing track. This will also disengage the drive cable. (Parts (30), (31), (32), and (43) are attached to (28).)
14. Separate panel front guide (28) from sunroof module (10).
15. Remove drive cable (8 or 9) and inspect for wear. Clean and lubricate with Mopar(r) Lubriplate white grease or equivalent. If one cable requires replacement, always replace both cables (8 and 9) as a set.
16. Repeat above Steps for other side.

INSTALLATION

NOTE: Drive cable return tubes (plastic) MUST be routed over the top of the drain tubes on module.

NOTE: The RH drive cable is longer than the LH drive cable. DO NOT interchange cables from side to side.

1. Insert drive cable (8) [RH] or (9) [LH] into rear end of track. Allow at least 50 mm (2 in.) to remain out of the track.
2. Engage front end of panel front guide (28) in sunroof module track and slide forward approximately 102 mm (4 in.) or until the cable end detail contacts the spring-loaded stop arm in the panel front guide. (At this time parts (30), (31), (32), and (43) should be attached to (28).
3. Guide the lock arm into the cable end slot.
4. Squeeze the drive cable and the panel front guide (28) together and push forward into track.
5. Slide panel front guide (28) forward so that the front edge is even with the front edge of the rear housing crossmember.
6. Engage actuating link (34) into sunroof module track opening ahead of panel front guide (28).
7. Hold actuating link (34) with one hand, and with the other, slide the panel front guide (28) forward until they contact (engage).
8. Slide the panel front guide forward until it stops. The panel front guide (28) MUST be to the front of the tracks on both sides to synchronize cables.
9. Engage front pivot of glass lift arm (35) in hole in actuating link (34). (At this time parts (27), (36), (35) should be attached to (37) as an assembly.)
10. Engage sliding roof panel cam block (37) to sunroof module track and install two screws (38) to hold it.
11. Repeat above steps for other side.
12. Install both panel down stops (47) onto tracks just behind front panel guides (28).
13. Position water trough (45) to sunroof module (10) and install 4 rivets.
14. Install sunroof drive motor (21). This will synchronize drive cables.
15. Install glass supports (3) and glass track assemblies (27) to glass lift arm assemblies.
16. Install glass panel (1).
17. Install sunshade (6).
18. Operate sunroof glass to closed position.
19. Install sunroof module (10) to vehicle. DO NOT tighten sunroof module retaining bolts at this time.
20. Tighten sunroof module retaining bolts (11).
21. Check and adjust glass height as necessary
22. Install both mechanism reveal covers (26).
23. Install headlining.