Sunroof Overhaul

Ensure smooth, leak-free operation of the sunroof.

Introduction

Those of you with a sunroof might want to read this, and perhaps more importantly - give it a go. The sunroof is basically a hole in the roof that you hope doesn't leak on your head some day. A little maintenance once in a while ensures smooth operation and leak-free enjoyment.

You'll especially want to do this if the following symptom manifests itself; you see traces of water running down the *inside* of your windshield after heavy rains or snow. What this indicates is that one or more of the four drainage outlets in the sunroof channel is clogged.

I usually do this once a year. If you don't park under trees or off-road, haul nasty stuff on the roof or such, you could probably do this less frequently.

Removal

  1. Remove the wind deflector via the four Torx screws, using the screwdriver located under the carpet in the cargo area. Set it aside.
  2. Disengage the latch. Open the sunroof and look rearwards at the latch and you'll notice two square black blocks adjacent to each hinge pin. While keeping the sunroof not quite locked in the open position and with slight tension upwards, depress each of these blocks fully with a screwdriver. The pins will release.
  3. Swivel the sunroof straight up, vertically. In order to do so, you'll need to sneak the sunroof past the rack tubing. It's a tight fit, but if you take care and push the rubber in a little you can get one side out at a time. A little shot of silicone spray on the rubber may help here.
  4. Slide the sunroof towards the driver side until hinge pins release. Once free, lift the sunroof straight up and out of the vehicle. Set it aside.

Cleaning

  1. Clean the drainage channel. Depending on the kind of grunge in there you may wish to use a paintbrush or toothbrush to get into the grooves. A little bit of soap and scrubbing should be enough. If you need a little more cleansing action, try a small squirt of Meguiar's #1 Paint Cleaner or Mother's Scratch Remover. Rinse with water thoroughly.
  2. Verify proper drainage. When rinsing with water, you'll find out quickly if the drainage outlets are working. If water pools in any of the four corners you should clear the blockage. Using a heavy insulated wire, snake it down the outlet until you feel it stop and chase with water a few times until cleared.
  3. Freshen up the rubber seal. Using an old rag and a can of silicone spray, clean and lubricate the rubber seal surrounding the channel. Do this numerous times until the rag does not get quite so black from oxidized rubber and starts to hold a bit of shine from the silicone. This preserves and softens the seal.
  4. Clean and grease hinge pins. Wipe off the hinge pins at the front of the channel and apply fresh grease.
  5. Prepare sunroof. Clean the sunroof by washing the whole thing with soapy water and rinse. When dry, apply oil to pivot areas of latch. Apply slight amount of grease to latch pins. If you have hard water stains on the outside of the sunroof, use a glass polish and follow up with wax. Clean and preserve the rubber seal as above.

Optional

  • You may want to wax the drainage channel and surrounding roof area, even standing inside the truck. Access will never be easier than now, and since the sunroof is out... Waxing the drainage channel will also make future cleanup easier and give it just a little extra protection.
  • If you have a "Thor (See Thru Deflector) Mod" now might be a good time to show it a little TLC. Grab the Plexiglas polish and give it a once over to restore shine and optical clarity. Follow up with a coat of wax.
  • If you've had a squeaky sunroof experience, try finishing off all the rubber seals with talcum powder -- the real thing, not the cornflower stuff often found in baby powder. No more squeaks or sticky seals.
  • The inside of the sunroof glass is a real pain to clean without leaving streaks. Best to wash it really well with soapy water and rinse. When mostly dry, wipe down in circles with a *very barely* damp paper towel or better yet, chamois. Blame it on the screen printing.

Finishing Up

  1. Reinstall sunroof. Basically the reverse of removal; align sunroof vertically over hinge pins. Slide it towards the passenger side to engage the pins and then sneak it down past the rack tubing again. Re-engage the latch pins and work the sunroof a few times to get the oil and grease worked in and ensure proper operation.
  2. Reinstall wind deflector. Align it with the four holes on the rack tubing. Apply a small amount of grease to the threads of the four Torx screws and re-install.

Conclusion

That's all there is to it. Depending on how cruddy things got under there this procedure takes varying amounts of time. After you do it once, it will be easier and more routine come the next time.