Sunroof - Inoperative/Opens By Itself
NO: 23-22-96GROUP: Body
DATE: Apr. 5, 1996
SUBJECT:
Sunroof Inoperative/Opens by Itself
MODELS:
1995 - 1996 (FJ) Avenger/Sebring/Talon
NOTE:
THIS BULLETIN APPLIES TO 1995 and 1996 VEHICLES BUILT BETWEEN MAY 1, 1995 AND JANUARY 19, 1996 MDH (05-01-XX AND 01-19-XX).
SYMPTOM/CONDITION:
The sunroof may open by itself or sticks in the open position. This condition can result from water traveling through the flocked drive cables into the sunroof control unit.
PARTS REQUIRED:
AR 04680370 Passive Restraint Grease
AR MR287457 Sunroof Drive Gable (Flocked) Left
AR MR287458 Sunroof Drive Cable (Flocked) Right
AR 04318025 Silicone Rubber Adhesive Sealant
1 MR199789 Sunroof Control Unit
1 06016155 Tie Strap
NOTE:
THE SUNROOF DRIVE CABLES LISTED ONLY APPLY TO VEHICLES BUILT AFTER MAY 1, 1995. TO IDENTIFY THE LEVEL OF ROOF ASSEMBLY, LOOK AT THE COLOR OF THE METAL GUIDE TUBES THAT THE CABLES PASS THROUGH. GOLD/COPPER COLORED TUBES WILL USE THE NEW FLOCKED CABLE LISTED AND SILVER COLORED TUBES WILL USE THE ORIGINAL (NON FLOCKED) CABLE LISTED IN THE PARTS BOOK. DO NOT INTERCHANGE DRIVE CABLES OR NOISE/BINDING WILL OCCUR.
REPAIR PROCEDURE:
This bulletin involves verifying sunroof drain tube operation, removing and lubricating the sunroof drive cables and installing a new control unit.
1. Remove the head liner to gain access to the sunroof components.
2. Remove the 6 sunroof glass screws and remove the sunroof glass.
3. With the sunroof in the fully closed position, remove the sunroof drive motor.
4. Pour a cup of water into the front corners of the sunroof housing to verify proper water drainage. If the sunroof does not drain properly, inspect the drain tubes for blockage. Repair as necessary.
5. Manually move both sunroof guide assemblies rearward by pushing on the guide tab. Remove both right and left rail rod holders (Figure 1).
6. Manually move the sunroof guide assemblies to the closed position. This will expose the drive cable attachments (Figure 2).
7. Using a small screwdriver, lift the attachment from the sunroof guide and pull the drive cables out of their tubes.
8. Inspect each cable for wetness and rust. If the cable is only wet, dry it with paper toweling and compressed air. If rusted, the cable(s) must be replaced with those listed in the parts required section of this bulletin.
9. After drying the cable or obtaining a new one, use the passive restraint grease P/N 04680370 and coat the entire surface of the drive cable. Use a small stiff brush and work the grease into the flocking.
10. Insert the lubricated drive cables into their tubes. Make sure the cables line up with the inner tubes when they pass by the motor attachment point (Figure 3).
11. Twist the drive cables to align the attachment ends as shown in figure 4. The attachment ends must be oriented as shown to prevent excessive movement and possible binding.
12. Manually move the sunroof guide assemblies to the closed position. Snap the cable end into their attachment on the guide assemblies noting the orientation as described above.
13. Clean the inner portion of the guide rail rod holder and apply a small bead of silicone sealer P/N 04318025 as shown in figure 5.
14. Manually move the sunroof guide assemblies to the open position. Clean any grease from the guide rail rod holder locations on the sunroof and inspect the drive cable tubes for proper position. The ferrule should line up with a slot in the sunroof assembly and corresponding depression in the guide rail rod holder.
15. Install the guide rail rod holders and tighten their screws.
16. Inspect the four drive cable tubes at the motor attachment location. The ferrules of each tube should be captured within the slots of the drive motor alignment plate (Figure 6). If any are out of position, use a screw driver and move them back into place before installing the motor. The plate may need to be flexed slightly to move the ferrules into place.
NOTE:
IF THE TUBES REQUIRE RELOCATION, DO NOT TWIST THE TUBE THAT COMES INTO CONTACT WITH THE CONTROL UNIT DRIVE GEAR. IF THIS TUBE COMES OUT OF POSITION, IT CAN CAUSE A RATCHETING SOUND AFTER ASSEMBLY AND/OR THE CONTROL UNIT TO COME OUT OF TIME (FIGURE 7).
17. Manually move the sunroof guide assemblies to the full closed position. Install the drive motor. Make sure the motor insert clip (located on motor) has not fallen off (Figure 8). A missing clip will result in motor ratcheting jerky sunroof operation or drive cable to gear disengagement.
18. Make sure the sunroof is in the fully closed position. Use a 5 mm hex wrench and manually rotate the sunroof motor to fully close the sunroof (Figure 9).
19. Using a sharp utility or modeling knife, shave off the two locating tabs on the top side of the new control unit P/N MR199789 (Figure 10).
CAUTION:
USE CARE TO PREVENT PLASTIC SHAVINGS FROM FALLING INTO OR AROUND THE CONTROL UNIT GEAR. THIS CAN OBSTRUCT GEAR MOVEMENT.
20. Check to see if the white dots are lined up in the top and bottom viewing window of the control unit. If they are, it indicates that the control unit is properly timed. If not, turn the gear located on the top side of the control unit until the dots are lined up (Figure 11).
21. Thread a tie strap, P/N 06016155, through the slot in the control unit retaining bracket (Figure 12). Position the strap so it will wrap around the center of the control unit with the head of the strap located at the front of the control unit when tightened.
22. Position the control unit cable tube so it will locate into the control unit gear. Tape can be wrapped around the cable tubes at the corner to help hold the tube in position (Figure 13).
23. Make sure the assembly is fully closed and re-install the control unit to the bracket. Hold the control unit on a slight angle while sliding it onto the bracket tab. Once located, push the control unit up to lock it into the bracket hole. Operate the sunroof to make sure the cable is positively installed into the control unit.
24. Tighten the plastic tie strap. Make sure the strap is wrapped around the center of the unit with the head of the strap located at the front of the unit. Cut off any excess tie strap after tightening.
25. Reinstall the sunroof glass, adjust height as necessary.
26. Test sunroof operation prior to re-installing the head liner.
Policy: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No: 23-30-64-90 1.7 Hrs.
FAILURE CODE: P8 - New Part