Sunroof grinding after stuck open.

[nykoda]

Today the sun popped out, so I decided to open up my sun roof and be happy. It went all the way back then made an ear wrenching sound as it got to the final stage. Trying to close it, one side would move, while the other was stationary. So I rushed home before the WA rain snuck its way in.

I read and read on the forum. Downloaded the TSB pdf for fixing these types of issues with the sunroof. Took everything apart, cleaned it, and greased it all. Super easy by the way. Put it back together and it closed. :thumb:

Well after opening it again to make sure my work was done I was greeted by the sound of the cog wheel grinding when it gets to its final position again. Then it wouldn't close again. So I held the tilt button for 15 sec and it started to close along with some grinding noise.

After holding it in the tilted up position and getting it to close properly where it should be sealed, it almost looks like its not quite sealed. The right side sits slightly lower than the other side. I poured water on it, and it didn't seem to soak through.

During the process I actually did break part of the left Guide Rail Holder. I'm thinking that this could maybe cause the problem of it not being level. As for it not moving like it should. Does the cog wheel on the motor have to be aligned just right? Is that where the grinding noise is coming from?

Was hoping someone with experience dealing with this could help me out. Thanks ahead of time everyone!

 

[shawnjohnson]

This happened to me last weekend after a day of chill cruising down some trails... I got it shut but the cracking and guides being off, I don't know if I'll ever open it again...

 

[T4RVB]

Same happened to me. I got it shut and disconnected the wire to the motor. No more sunroof.

 

[sgvnut]

Same thing happened to mine. I got it to close and never opened it again. It is still a bit loose though. It makes a slight rattle sometimes when I'm driving on the freeway. I can push up slightly on the glass and it moves a bit, doesn't seem to leak in the rain though.

 

[07V8]

Same happened to me. I got it shut and disconnected the wire to the motor. No more sunroof.

How did you get to the wire. I can't figure out how to get the control panel from the ceiling.

 

[nykoda]

lol its sad that we have to come to the point of never using our sunroofs again. I am hoping to get to get the outcome of being able to use it again.

Here's some pictures to go along with my TSB process.



Pop out the Control Console:




Gear Assembly:




Next take un snap the Rail Guide Holders and slide them out:




Remove the Wind Gaurd:


Pry out the Control Wire and slide out the Black Holder:


Scrape and clean all the old grease off everything and get it all lubed up with some new.


Then put everything back together.

 

[nykoda]

How did you get to the wire. I can't figure out how to get the control panel from the ceiling.

Just pop it out with a flathead screwdriver. Start on the side nearest to the front window. Pry it till you can get your fingers in there and give it a tug. You shouldn't break any clips.

 

[CXS]

Odd, I just hit the buttons over and over and it made some nasty noises until it worked again.

 

[nykoda]

Odd, I just hit the buttons over and over and it made some nasty noises until it worked again.

Yeah I can get mine to work by holding the button down for 15 sec but it's making that horrible grinding noise. That's why I'm thinking something about the cog wheel on the motor has to be the issue.

 

[green_manalishi]

Yeah I can get mine to work by holding the button down for 15 sec but it's making that horrible grinding noise. That's why I'm thinking something about the cog wheel on the motor has to be the issue.

I researched this a bit before, and I seem to remember the culprit being mis-aligned cables... Or something like that. But no one seems to have ever fixed it for good short of replacing the entire unit.

I've tried the TSB and alignment procedure but nothing seems to help.

I wish you the best of luck, though. Sure would love if there was a way to fix this.

 

[IOPturbo]

Mine ended up needing to be replaced. Took about half a day to R&R. I picked up the assembly from a junk yard and cleaned and greased it before install. If anyone goes this route the crossbar that is riveted on is different if you have the rear seat entertainment crap that I've never used. Had to drill it and use screws to make it work.

 

[green_manalishi]

Mine ended up needing to be replaced. Took about half a day to R&R. I picked up the assembly from a junk yard and cleaned and greased it before install. If anyone goes this route the crossbar that is riveted on is different if you have the rear seat entertainment crap that I've never used. Had to drill it and use screws to make it work.

Could you tell what it was that failed?

 

[CXS]

Yeah I can get mine to work by holding the button down for 15 sec but it's making that horrible grinding noise. That's why I'm thinking something about the cog wheel on the motor has to be the issue.

I held it down through the noise for a few open / close cycles while it made the noise and after a few attempts it worked. I figured it was shot and couldn't hurt it any more so went for it. I'm guessing it won't last forever but it's working fine now. It's even quiet!

 

[BlackWorksInc]

Usually it's the cables that start sticking/binding, sometimes it some track pieces when they get forced.

This is mainly why I say sunroofs are just an inevitable waste of money.

 

[RonJR]

Did Toyota's sun roof quality go down with the 4th gens? The sun roof on my '94 has never given any trouble in 212K miles and 22 years (and I use it almost daily in the summer time), and I don't think I've ever read about a sun roof problem on the yotatech 2nd gen forum.

But, now that I've got the '06, sun roof issues seem to be a fairly regular topic on this 4th gen forum. Makes me think quality has slipped over the years.

 

[svana]

Just an FYI I had a 100% shutdown of mine last year or so. Got to the point where it wouldn't move at all, just grind. Pulled everything out, cleaned it, still wouldn't work. Turns out the spline had been rusted stuck to the inside of the metal routing pipe. Literally had to take a dremel and cut the pipe in half while making sure to not nick the spline inside. Took the spline out, cleaned it up, then went and bought some soft copper tubing from Home Depot (the stuff they use for kitchen appliances) to fabricate a replacement housing. Bent the tube, tapered and flared the end (outer diameter was too big for the slot that it fits in) to get it to lock into the motor housing, then reassembled everything. Works like new at this point. How long will it last? Not sure. Would I probably do the same thing again if/when the other side goes? Probably. I guess I just really like my sunroof lol

 

[green_manalishi]

Just an FYI I had a 100% shutdown of mine last year or so. Got to the point where it wouldn't move at all, just grind. Pulled everything out, cleaned it, still wouldn't work. Turns out the spline had been rusted stuck to the inside of the metal routing pipe. Literally had to take a dremel and cut the pipe in half while making sure to not nick the spline inside. Took the spline out, cleaned it up, then went and bought some soft copper tubing from Home Depot (the stuff they use for kitchen appliances) to fabricate a replacement housing. Bent the tube, tapered and flared the end (outer diameter was too big for the slot that it fits in) to get it to lock into the motor housing, then reassembled everything. Works like new at this point. How long will it last? Not sure. Would I probably do the same thing again if/when the other side goes? Probably. I guess I just really like my sunroof lol

Is that accessible without removing the headliner?

 

[rooost]

Go back in TIME, Clean and Reup the serving of White lithium grease

 

[svana]

Is that accessible without removing the headliner?

No, had to take the whole thing down to get the mechanism out.

 

[nykoda]

I held it down through the noise for a few open / close cycles while it made the noise and after a few attempts it worked. I figured it was shot and couldn't hurt it any more so went for it. I'm guessing it won't last forever but it's working fine now. It's even quiet!

I did this too... And it worked...

No noise. Opens and closes just like before. Wierd.