Toyota 4Runner Forum - Largest 4Runner Forum - BO001R-05 11/30/2005 Body - Sunroof Components and Service Procedures

NOTE: This bulletin has three sub bulletins.

Body - Sunroof Components and Service Procedures
Information
Body - Sunroof Components and Service Procedures
Repair Procedure: Removal
Repair Procedure: Reassembly

#1
BODY
BO001-05
REVISED

Title:
MOON ROOF REPLACEMENT PARTS

Models:
'03 - '05 4Runner

January 12, 2005

TSB REVISION NOTICE :

^ November 30, 2005: The note in step 9 of the "Repair Procedure: Removal" section has been updated. In the "Repair Procedure: Reassembly" section, the illustration in step 19 has been clarified, and a note has been added to step 20.

Previous versions of this TSB should be discarded.

Introduction

A complete moon roof (sliding roof) assembly is no longer available as a service part. The moon roof (sliding roof) assembly has been separated into three serviceable parts. This bulletin provides information on the three serviceable parts and replacement procedures.

Applicable Vehicles

2003 - 2005 model year 4Runner vehicles.

Parts Information

Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Components

#2
Moon Roof (Sliding Roof) Housing Sub-assembly

Refer to the Technical Information System (TIS), 2003 to 2005 model year 4Runner

Repair Manual for moon roof housing sub-assembly removal and installation procedures:

Sliding Roof/convertible: Sliding Roof: Replacement

1. Remove roof headlining assembly. Please refer to TIS, applicable model year 4Runner Repair Manual: Exterior/Interior Trim: Headlining Assy: Replacement.

2. Remove sliding roof guide rail cover LH.

Using a taped screwdriver, pry out the rail cover.

3. Remove sliding roof guide rail cover LH.

4. Remove sliding roof guide rail cover RH.

5. Remove sliding roof side garnish LH.

6. Remove sliding roof side garnish RH.

7. Remove sliding roof glass sub-assembly.

A. Using a Torx wrench (T25), remove the 4 screws.

B. Pull the glass upward to remove it.

8. Remove sliding roof
housing sub-assembly.

A. Disconnect the 4 drain hoses from the housing.

B. Remove the 8 bolts and 4 brackets.

C. Remove the 6 nuts and housing sub-assembly.

9. Remove white end caps from the rear of the housing assembly.

NOTE :

^ Make sure NOT to lose or damage the foam tape on the end caps. This tape is used to prevent waterleaks. Also, make note of the correct position of the end cap to aid in reassembly.

10. Remove rear drip bar.

11. While holding slide, move cable shoe rearwards to end of travel. Then push slide rearwards approximately 6 inches.

12. Remove wind deflector retaining clip (both sides).

Push down on tab, pull up on rear.

NOTE :To prevent breakage of the guide block release lever when the outside temperature is below 40°F (4°C), use a heat gun to raise the temperature of the guide block and surrounding aluminum housing to a temperature of at least 65°F (18°C). Be careful NOT to damage components or paint with the heat gun.

13. Remove wind deflector.

14. Move slides to most forward position and then while holding slides, move cable shoes forward so roof is in full tilt-up position.

NOTE :Keep slide tab in the middle of the cut-out in the moon roof assembly for ease.

15. Move front of slide bracket rearwards until Phillips screws are exposed 2 screws on each side.

16. Remove the 2 Phillips screws from each side.

17. Remove front drip pan/drip rail. Unhook cable overflow housings from frame. Pull up on frame to remove drip rail. Cables will slide out of housings.

18. Release wind deflector actuator rod from front clip.

19. Remove front wind deflector actuator clip.

20. Grab shoe and push it out the front of the moon roof housing.

21. Remove actuator rod clips (both sides).

22. Remove actuator rod (both sides).

23. Remove garnish slide (both sides).

24. Remove end plug (both sides).

#3

NOTE :During reassembly, lubricate all moving components and track with Body Grease W.

1. Install end plugs.

2. Install garnish slides.

3. Install actuator rods.

4. Install actuator rod clips.

NOTE :Make sure actuator rod and actuator rod clips are fully seated.

5. Slide bracket assembly and cable assembly into front of housing.

NOTE :Sliding bracket assembly and cable assembly must be installed at the same time.

6. Push back far enough to allow access to the screw holes. Brackets should be in the full tilt-up position.

7. Reinstall wind deflector actuator shoe.

8. Slide actuator rod into shoe.

NOTE :Make sure rod is fully seated.

9. Slide cables into metal cable housing.

NOTE :Make sure metal cable housing clips into frame sub-assembly before attaching drip rail.

10. Install front drip rail.

11. Install 2 Phillips screws on each side.

12. Align tab in the cut-out in the housing assembly.

13. While holding slide, move cable shoe rearwards to end of travel.

14. Push the front of the sliding bracket back to clear the front wind deflector shoe.

15. If previously removed, install wind deflector springs onto wind deflector.

16. Install wind deflector and wind deflector clips.

NOTE :Install front tab first, then slide back and snap into position.

17. Holding wind deflector down, move cable shoe forward to timing marks.

18. Install rear drip bar.

19. Install white end caps onto rear of housing assembly.

20. Install moon roof housing sub-assembly into vehicle.

Refer to TIS, 2003 to 2005 model year 4Runner Repair Manual for moon roof housing sub-assembly removal and installation procedures: Sliding Roof/convertible: Sliding Roof: Replacement.

NOTE :

^ Make sure foam tape is added between the end cap and housing assembly.

^ Also ensure the end cap is positioned correctly to prevent over travel of the sun shade