1998 Discovery sunroof trouble shooting and repair

[Dach Savage]

Hi all, trying to repair both sunroofs on my `98 Discovery 1 and am not finding much in the way of parts or repair techniques on the net. It appears that I will need to remove the headliner in order to get to the slides and parts, cannot seem to even get the glass out without dropping the headliner. From what I can see so far the linkage on the sides is broken where it slides in the track and one of the diecast arms is bent/broken. Anyone car to shed some light on the service proceedure or links to parts suppliers (aside from LR that is). Thanks Dach.

 

[discostew]

I take the whole mechanism out of the truck and work on it upside down on a trash can . The row of torx head bolts around the inside of the opening can be had with a 1/4 drive stuff with the headliner in the car but hanging down a little . once the tray is off the assembly it just lays on the headliner . The roof will push out the opening upwards but its going to be stuck like a bitch . Your gonna need slides with cables , should run you less than $150 . But better check that there still available . Sometimes I have to beat the roof out of the opening with a modified baseball bat I use like a drift .

 

[Mudy_ovl]

I tried to repair/rebuild my sunroofs, but after trying to replace the drive cables and re-sync everything, I found this following process easier (which includes much of what DiscoStew said, BUT you will need to source an entire, working sunroof assembly (SRA) from a junk yard or DWeb member.
1) Lower headliner
2) Remove Torx screws, detach drain tubes and disconnect any wiring.
3) Lower inside frame retainer and set aside.
4) Gently, but firmly, push up on the perimeter of the SRA. (as DiscosStew stated, this will take some time and force as the assembly is sealed to the roof of the vehicle.) It will pop a little, but as long as you are push on the perimeter frame, you should be good to go.
5) Once loose, take SRA on the roof.
6) Remove any old sealant around the opening. Surface should be clean for new sealant.
7) Temporarily connect wiring and test sunroof for functionality. Connectors should match up.
8) Now, lay down a bead of sealant about 1/4"-3/8" tall. This is to seal the gap under the exterior, perimeter frame.(I used clear silicon so it wasn't too visible).
9) Carefully place the SRA into the open and push down to compress the silicon bead.
10) Re-install the inner retaining frame and torque down screws. (clean excess sealant where it has oozed out from under the exterior frame)
11) Re-attach wiring and drain tubes.
12) Raise headliner.
13) Crack a cold one if you haven't already and enjoy your non-clicking, non-crackling, non-functioning sunroof.

-Chris D.

 

[Rocky]

What kind of front bumper is that??????

 

[discostew]

Timing the roof is simple . The service procedure lists the gap thickness at the front edge of the glass . I have a couple spacers I filed down and they sit in that gap , then you torque the 4 bolts that hold the glass to the tracks . Then you line up the drive gear on the motor with the mark on the motor itself before bolting it to the assembly .