My sunroof rattles on my 2003 Disco when open because of the missing nylon/hard plastic donut that fits around the post in the arm that runs along the track in the rail. I have been thinking about carving two bushings out of a nylon washer. has anyone done this and how sensitive is the sunroof glass, I'm worried that I might crack the glass when reinstalling the rails. Also, is there a replacement kit for these rails that I can just replace instead of having to carve these little bushings?

Thanks, Walt

 

Just leave it closed and dont worry about it.
I dont open mine because it messes up my hair.
I do not know the answer to your question.

 

Thanks for the response Spike I don't mind leaving it closed, but since the bushings are missing, the glass sits up just a bit and the wind noise at highway speeds is annoying the ever lovin' crap out of me. I am going to remove the glass so that I can squeeze in 2 home-made bushings. I've read where sunroof glass gets torqued to 4 ft/lbs. here goes, if the glass breaks, Roveland has replacement glass. I'll let you know how it goes.

 

You can order new sunroof rails. I picked mine up off ebay but all the Rover parts places sell them. They are not difficult to install and you can do it without completely removing the headliner. You just need to drop the headliner enough to access the screws. Leaving the sunroof closed is an option but if it's rattling it's not going to help your case. Personally I like opening my sunroof, and unlike Spike I have hair to mess up. The sunroof glass is pretty tough. It won't take being drop but no need to be scared to handle it. It has to meet the same safety standards as the windshield or any other window in the truck.

 

Good point on the safety standards.

 

Hello!!!

How did you solve this problem? I have a simiar problem because the bushings in my sunroof rails are also missing and both sunroofs are not working.

Did you made the bushings or purchased the new rails?

Thanks!!!