Well, here's an update to my frustrating adventure:

So far I have gone in three times to the dealer for this roof/headliner rattle. The first time they simply installed the "quick fix" kit and failed to test drive it to REALLY see if it worked -- it only slightly improved the condition. Still a rattle in the plastic side arms of the moonroof and elsewhere.

Next time, came back in after the rattle got worse - even on smooth pavement I have an incessant rattle! This time they "tightened and adjusted" the moonroof - of course this took all day and although it improved somewhat again the rattling is still there. They then decided to order a new rubber seal for the moonroof itself - they said the current seal seemed to have some play in it.

When I came back for round three, the parts had arrived but it was a whole new moonroof assembly - but WITHOUT the rubber seal - i.e. totally useless to me - so they did NOTHING and had the car at the dealer all day again.

Now it seems that seal / assembly is on back order because Toyota in their inifinite wisdom finally realized that this is a chronic problem and the orders are coming out of the woodwork. Perhaps the part will be in next week... I am seriously regretting ever getting the Moonroof option now - perhaps next time I go without it and at least have a *QUIET* vehicle!

++FRUSTRATED++
2003 4Runner Sport 4x4 v8 w/ rattle