Sunroof won't slide!

[HorseOffaGypsy]

My sunroof on my 94 Passat has stopped slide opening! The tilt works fine - so I'm guessing that the motor is OK. It started a few days ago, when you went to slide the sunroof, before it started to move is made a loud "clack" sound and then slid away. I didn't like the sound of this so thought it must be sticking somewhere. As whenever something is sticking, I immediately got the WD40 out and sprayed the rails.... the sun roof no longer slides at all!

Any ideas why the "clack" sounded, or how to get the sunroof out?

[erico]

My sunroof on my 94 Passat has stopped slide opening! The tilt works fine - so I'm guessing that the motor is OK. It started a few days ago, when you went to slide the sunroof, before it started to move is made a loud "clack" sound and then slid away. I didn't like the sound of this so thought it must be sticking somewhere. As whenever something is sticking, I immediately got the WD40 out and sprayed the rails.... the sun roof no longer slides at all!

Any ideas why the "clack" sounded, or how to get the sunroof out?
Mine is a 97 but it should be pretty similar.
Volkswagen > Passat > 1995-1997
Body Exterior, Interior
60 - Sunroof
Sunroof Assembly, Removing and Installing
Removing
http://ebahn.bentleypublishers.com/icons/blank.gifDisconnect Ground (GND) strap from battery.

Unclip interior light.

Remove screw - 1 - and - 2 - and unhook cover for electric drive motor in direction of - arrow - .
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Note:
http://ebahn.bentleypublishers.com/icons/blank.gifScrews - 1 - secure angle bracket - 3 - at the same time.
http://ebahn.bentleypublishers.com/icons/blank.gifRemove weather strip from molded headliner cut-out (for assembly aid, the replacement part weather strip is delivered with a rubber strip in clamping channel).

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A clearance cut of - a - = 180 mm remains in area of electric drive motor when installing.
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The clearance cut is identified by notches in the frame.


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Remove trim at A-pillar, B-pillar top, C-pillar top, and D-pillar.


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Remove molded headliner.


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Disconnect water drain hoses - arrows - from sunroof assembly.



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Remove electric drive motor.


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Remove glass panel for sunroof for improved installation .


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Remove bolts and remove installation unit from the vehicle with a second mechanic.


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Note:


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The sunroof assembly can also be removed complete.


Installing

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Place sunroof assembly on rear mounts and fold upward (the three locating pins must engage in holes in mount).


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Tighten installation unit to 7.5 Nm.


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Note:


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If the function test is performed without the molded headliner, the weather strip must be installed first.


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Copyright © 2006 Volkswagen of America, Inc. and Bentley Publishers. All rights reserved. Last processed:

Hope this helps you. It is from the Bentley manual for 1995-97 models. My 1992 Corrado SLC had the same basic setup as is described in the text. The clack sound was one of the metallic clips breaking --> See the last image that I posted.
The difficult part of this job is removing the inside roof lining and trim. Been there, done it and it was not fun. :)

Cheers,
Eric

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