Other than caulk. I do like the functionality of the sunroof, when it functions. I will be digging into this in an hour or two and will post pics when I do.

Here's what happened: the sunroof is held by two parts. One is a pivot pin and the other is a pin that moves in a sliding track. The second pin, and the vertical flange that supports it, got bent inward somehow. Consequently the sunroof can fall off of the tracks in the back. It has not happened before now, and I would say I use the sunroofs perhaps once a week except in winter.

So today my sunroof jammed for the first time. As it was opening, after 2-3" it started going sideways. So I gently pushed on it to try to get it back on track, and it opened normally. When I went to close it, it again jammed sideways. So I stood on the door jamb to reach the roof, jiggled the glass a bit, and both back pins popped out of the track. Now it pivots at the front pin, and I don't want to drive it until I come up with a fix. That means I've got to come up with something before Saturday's run to the dunes.

My questions are:
1) Is this specific failure mode common? I know these fail, but the specific issue of the pins being bent inward and no longer retaining the glass, is that common?
2) Any pointers from people with the same problem? Other than caulk (which would still require getting the window closed)?

My shot-in-the-dark solution is:
Now the the glass is pivoted up, unscrew and remove it. Bend the clips back to the correct orientation with vice grips. Pivot the glass holding pieces back toward the rear pin, position in place. Remove headliner??? Get tracks into a secure closed position, place glass on tracks, install screws again, and have (hopefully) a properly functioning sunroof.

Any easier way to do this, or potential hang-ups, or other things to do at the same time? I have most of an afternoon to devote to it today, and at least a couple hours tomorrow morning. At some point in that time window I'm also hoping to fabricate my dune flag holder.

 

Hello. I think the best you can do is to buy the sunroof rails. The price is between 60 to 80.

land rover sunroof rails | eBay

The metal used to build those pins will break if you try to unbend it, so... not advisable that you try to fix it.

Mines had the problem that the base of the flexible wire that connects the sunroofs with the gear wheel in the sunroof motor is broken. When I was trying to fix this, then also tried to unbend those metal pieces and the only I got was two of them broken.

 

Call Will Tillery and see what he has to offer as far as parts and maybe a quick question on how to fix it.

 

So would a sunroof assembly from a 2004 DII work? The whole thing on mine looks like it will fall apart soon, and only one side is moving. I can get a complete DII assembly for just over $100 including everything but the motor. My motors are still good.

So if that would work, I think I have a solution. For now I'll just try to get mine closed and sealed, then order the replacement assembly ASAP.

 

Okay, so I stripped nearly the whole interior so I could put it back together, and will leave the interior apart until I get a replacement. In fact, I may dig deeper so I can find and eliminate any water leaks/rusty spots before reassembly. I managed to close the sunroof, and I unplugged the motor so I won't accidentally open it again. I'm pretty sure the DII sunroof is the same, but am trying to verify my sources. Also, are the front and rear assemblies identical? They look like it to me.

 

Front and rear sunroofs are identical. - have exchanged mine and no problems. Also, D1 and D2 are the same but you may find different part numbers. This is because in the disco 2 the grass, rails and bin is sold as a complete assembly, but in the disco 1 each part has its own part number. Please let me know if you get the sunroof replacements because I would like to have your rails if possible.

 

Good to know. So is it still possible to replace the individual parts on the D2 version using D1 part numbers? That would be good to know before I take the leap. Yeah I will let you know what I decide to do, for now I'm just driving around with no headliner or interior panels, and the old one disabled...

 

Just ordered a complete 2004 DII assembly minus glass and motor for $100. Should be here in a week or so. I managed to close the existing sunroof and am leaving the interior bare until I finish the swap. When I'm done, I guess I'll just figure out what (if anything) is still good from the old unit.

I was planning to fix it, replace individual parts, but since I got an assembly so cheap the swap makes sense.

 

Please post pics, I have to tackle mine this summer as well. The right side of my front roof is loose and is trying to take out the left side. I have to hold my hand on the roof to keep it even when I push the button to open it. Still closes fine for now.

 

I'll post pics later, I haven't done much on it yet. All I did for the time being was strip the interior, remove the glass, reposition the rails to the closed position, and reinstall glass. Then I plan to swap the unitized assembly later.