2009 V6 4wd Limited:

Recently the glass sunroof panel started moving around, squeaking, and making a huge amount of noise ratting around in the airflow at highway speed. It’s quite loose on the left hand side in particular – moves up and down quite a bit, and on the LHS the panel sits ~1/4" below the roof level on the body which I reckon is one reason it’s so loud on the highway.

I brought it over to the dealer. Our local Toyota dealer service guys are just okay; definitely have been to better. Asked them to readjust the sunroof to spec so that the glass sits tight and flush with the roof, so it’s nice and quiet like it’s supposed to be. Figured they would know what to do.

Well ... nope. They said the tracks are extremely worn and that I need a new sunroof assembly. Has to be total BS that the tracks are worn, since I hardly ever open it ... how could they just get worn?. And a new assembly is $6,170, with their labor. Yikes!!! Forget that!!!

Is there a shim or something that might have fallen out on the LHS? Is there any way to tighten up the assembly? I have zero familiarity with these mechanisms and I don't want to make the problem worse. If someone could explain, I am certainly willing to give it a try though. I have plenty of Torx drivers and whatnot.

Any heads-ups massively appreciated.

I feel like some of the issues that develop are a result of the seal around the sunroof glass drying up/getting smaller over time. What I did was apply electrical tape (good stuff, 3M Super 33+) around the inside of the body where that seal rests against to tighten it back up. Helped cure the sunroof rattle I had. Really wish I didn't have a sunroof at all since it never gets used.

Hey guys I thought I would record here how this was finally licked.

The stupid Yoda dealer near here followed up with me after their diag and offered to replace the entire sunroof. Cost for that work was $6,170!!!!! I told them to go pound.

I then Googled a nearby place that installs aftermarket sunroofs, and had really great reviews. Drove up there. Super nice people and obviously obsessed with the details of these things. Inspected it for free, and they said the timing was off as between the L and R -side cables that pull the sunroof open and shut; the L side wasn't pulling the latch into final position. But they also said a new rubber gasket/surround for the glass would help immensely, and suggested I try to locate one and they'd install it.

Well, turns out that Toyota does not sell the rubber surround independently. You have to buy the whole glass, which comes with the rubber pre-attached. The part # is 63201-35084. The stealer wanted $872+tax for that part; I said nfw. Got some quotes and the best I could find for a new OEM Toyota unit was $449.96 delivered including tax. Decided to bite the bullet and order one. Received it.

Brought it up to the sunroof place, and they installed it in 45 minutes and then re-timed the two cables. Beautiful job. Now the roof doesn't rattle over bumps, operates smooth as glass, and is dead quiet even at highway speed. They charged me $100 cash which seemed totally fair.

The rest of the vehicle is in perfect condition, and I've kept up with undercoating etc., so it seemed to me like $540 to correctly solve this problem once and for all wasn't so ridiculous. All I can say is, stay away from the Toyota dealer service department ... those guys are the absolute worst!!!

Please share where you found the replacement for $440, it will most likely help others that need the part!

I got it from a Toyota parts specialist in Dubai. Can't remember the name but I'll look. There are tons of parts dealers there. Yoda 4WD components are dirt cheap in the Middle East. They DHL'd it and I had it in about 10 days. You just have to be 100 percent sure you have the right part #, because the return shipping would be appallingly expensive.

This is something I hadn't considered and I have a fresh roll just sitting! How did you remove the trim rubber without any damage? Mine would only need a light shim so this could be the fix I've been waiting for (plus stopping the 2 rods from clattering).

I didn't remove the trim around the sunroof glass, just added the electrical tape to the painted area on the body where the seal would sit which made the glass fit tighter.