A Quest to fix my Sunroof - Subaru Outback - Subaru Outback Forums
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post #1 of 13 (permalink) Old 07-09-2016, 12:21 PM Thread Starter
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A Quest to fix my Sunroof

So I have my 2005 Outback, H6 with 88k and we are in the process of getting a few things fixed. Yesterday at the dealership they took a look at my sunroof/moonroof combo. The first piece of glass normally pops up, then the latter part slides back. That first piece of glass pops up on the passenger side, but the driver side doesn't pop up. The sunroof is then stuck at this point, and it won't open or close.

So I remove the glass at this point (which has a lot of tension upon removing the 4 bolts). I can then open the sliding glass all the way. Inspecting the sunroof tracks I notice a difference. On the passenger side the track looks like this:


The driver side looks quite a bit different:


Notice how the plastic piece moves away from the track (upward in the orientation of this picture below)


I can push the plastic mechanism back in (downward in the above photo) and slide it to match the point on the passenger side. I can put the glass back in and everything closes like it is supposed to, proceeds to open and everything. Normal operations. Then it stops working, and that plastic piece pops back out of track again.

Until the next day, then it repeats the process. I took it to the dealership and they told me I need a new sun roof assembly, $1,200 in parts and $700 in labor. Surely I can permanently fix this plastic piece without needing to replace the entire thing right? I am going to try to do just this.

So with this, does anyone have any pointers? I think at this point I am going to pull the head liner down and pull out the entire assembly to inspect it.

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post #2 of 13 (permalink) Old 07-15-2016, 07:01 PM
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Quote:
Originally Posted by 2k.jacob View Post
So I have my 2005 Outback, H6 with 88k and we are in the process of getting a few things fixed. Yesterday at the dealership they took a look at my sunroof/moonroof combo. The first piece of glass normally pops up, then the latter part slides back. That first piece of glass pops up on the passenger side, but the driver side doesn't pop up. The sunroof is then stuck at this point, and it won't open or close.

So I remove the glass at this point (which has a lot of tension upon removing the 4 bolts). I can then open the sliding glass all the way. Inspecting the sunroof tracks I notice a difference. On the passenger side the track looks like this:


The driver side looks quite a bit different:


Notice how the plastic piece moves away from the track (upward in the orientation of this picture below)


I can push the plastic mechanism back in (downward in the above photo) and slide it to match the point on the passenger side. I can put the glass back in and everything closes like it is supposed to, proceeds to open and everything. Normal operations. Then it stops working, and that plastic piece pops back out of track again.

Until the next day, then it repeats the process. I took it to the dealership and they told me I need a new sun roof assembly, $1,200 in parts and $700 in labor. Surely I can permanently fix this plastic piece without needing to replace the entire thing right? I am going to try to do just this.

So with this, does anyone have any pointers? I think at this point I am going to pull the head liner down and pull out the entire assembly to inspect it.
Let me know if you find a fix. My sunroof did the same thing and I got it closed after some work. Now I haven't used it for two years!


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post #3 of 13 (permalink) Old 07-15-2016, 07:23 PM Thread Starter
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Originally Posted by spacematt View Post
Let me know if you find a fix. My sunroof did the same thing and I got it closed after some work. Now I haven't used it for two years!
Will do! It seems like it would be simple to fix... Just waiting for a break from the weather to look into it...

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post #4 of 13 (permalink) Old 10-27-2017, 05:59 AM
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Old thread, same problem on the Outback I just bought. The small rods often rods pop out. One of them has no more plastic stuff around. Does anyone have a solution?

Thanks


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post #5 of 13 (permalink) Old 10-27-2017, 06:49 AM
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Just to add to this list, I have the same problem with my 2005. One slider (as pictured above), is missing a small, plastic sleeve around the little "spindle" part that locks into the aluminum rail. The other clip is broken-off completely.

From my inspection, it looks like complete removal is required in order to disassemble the sliders and tracks. The service manual goes as far as glass removal/install and re-initializing the motor/timer, but that's it. The end-caps of the tracks are sealed with black RTV and I believe the whole assembly is "glued" to the roof to seal it (rather than a replaceable rubber/foam seal).

I believe this is one the few systems in the car to be a "black box": you just remove and replace the whole assembly.

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post #6 of 13 (permalink) Old 10-27-2017, 06:58 AM
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Originally Posted by RoughDiamond View Post
Just to add to this list, I have the same problem with my 2005. One slider (as pictured above), is missing a small, plastic sleeve around the little "spindle" part that locks into the aluminum rail. The other clip is broken-off completely.

From my inspection, it looks like complete removal is required in order to disassemble the sliders and tracks. The service manual goes as far as glass removal/install and re-initializing the motor/timer, but that's it. The end-caps of the tracks are sealed with black RTV and I believe the whole assembly is "glued" to the roof to seal it (rather than a replaceable rubber/foam seal).

I believe this is one the few systems in the car to be a "black box": you just remove and replace the whole assembly.
Indeed the FSM is not very eloquent; yet some spare parts are available: https://www.subarupartsamerica.com/p...bgroup=SUNROOF

I believe some people had the courage to disassemble it :P


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post #7 of 13 (permalink) Old 10-27-2017, 10:31 AM
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Back when I had an XT, I went through this predicament. i ended up buying a used sunroof from a junkyard and replacing mine with it. Even the "new" one had an issue but we were able to fix it. The install is challenging but not impossible. Basically you just need to remove the glass from your old one, remove the headliner and pillars, unbolt the old one and unplug it, and remove it. Set aside a full day and get a second set of hands and it should be doable!

Honestly my current OB doesn't have the sunroof, and I'm pretty thankful for that. Too many problems with those things.

Good luck!
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post #8 of 13 (permalink) Old 10-29-2017, 04:29 PM
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Many of the plastic parts are removable from salvage yard cars. You just need to be very careful removing them. And DONT tell the yard guy you need sunroof parts. They want to sell the complete assembly. Which Rarely occurs.

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post #9 of 13 (permalink) Old 05-27-2018, 10:29 PM
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I recently picked up my OB and it has the same issue. Looked at it all afternoon and decided that a simple guide would keep this spring loaded piece from popping out.

Luckily I have access to a 3D printer and am going to print a small plastic guide (image) that I plan to epoxy against the side of the track. Seems to be plenty of extra space in there and I prototyped with aluminum foil and it worked, just deformed after a few open/shut cycles.

I'll post results here soon.
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post #10 of 13 (permalink) Old 04-24-2019, 03:13 PM
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Quote:
Originally Posted by Ma_XT View Post
I recently picked up my OB and it has the same issue. Looked at it all afternoon and decided that a simple guide would keep this spring loaded piece from popping out.

Luckily I have access to a 3D printer and am going to print a small plastic guide (image) that I plan to epoxy against the side of the track. Seems to be plenty of extra space in there and I prototyped with aluminum foil and it worked, just deformed after a few open/shut cycles.

I'll post results here soon.
Hi! Any updates on this?


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