So with spring right around the corner (hopefully) I'm going to have to un-tape my sunroofs shortly.

One interesting thing I noticed.. I taped the rear one from the glass to the paint (using black duct tape) because you can't really see it. I taped the front from the glass and over the plastic sunroof trim THEN cut the remainder around the base of the plastic so the tape didn't touch the paint, since you can kinda see the front sunroof.

Wellllll, guess what's still leaking?

I was pissed at first but now I'm almost happy. I've spend countless hours repairing the front sunroof, to the point where I opened it, dropped the headliner and poured gallons of water inspecting for any possible scenario where something might leak into headliner. I THOUGHT I fixed it. With the tape where it is now, ZERO water can enter up there except around the plastic trim that sits on the paint.

Has anyone ever experienced a leak in this location before?

The rear is a different story, but since the glass is locked shut *AGAIN* (I already replaced the motor w/ used ebay one but whatever..) I'm going to leave that one sealed up for now.

 

I've installed a number of sunroofs over the years in vehicles that didn't come with them. That area is the area I overkill when installing. I use Black GE 50 year silicone there and make sure it presses out of both sides of the gaskets, then wipe clean. Never had a leak...

 

D2's sunroofs leak in mainly two places 1) from the cr*p plastic drain tubes/sumps fitted to each sunroof frame at both front outside edges. 2) around the frame where it seals to the truck roof where the plastic trim also adjoins the roof. As SS says, always seal the sunroof frame in well with high temperature good quality silicon mastic, I personally use silicon marine mastic but auto body mastic is probably as good. The problem is that as the truck ages and goes through heating and cooling cycles from the ambient temperatures together with the bodywork flexing the original mastic hardens and then cracks, and, hey presto, you have rainwater pi55ing into the headliner which then screws that up as well and the material starts to sag. It's an awful and boring job to do but it'll take a good weekend to fix the sunroofs and renew the headliner material whilst it's out. If you have a rear, 2nd sunroof and rear AC, it's a bit more complicated as you have to remove the AC ducts (drill out the pop rivets) above the headliner to get the sunroof out. Guess what I've got - yep, you're right, rear AC and a rear sunroof.

A few useful links:

http://www.is-us.co.uk/vehicles/sunroof-repair-01.html

http://www.lrrforums.com/showthread....-the-headliner

http://forums.lr4x4.com/index.php?showtopic=77630

http://forums.lr4x4.com/index.php?showtopic=31484

 

Anyone know how to repair a broken sunroof nipple?

 

Glue.

 

I was thinking of something different than just glue. It looks like the previous owner tried just glue.

 

try picking up a plastic ****** fitting from HD or Lowes and JB wield it in place, maybe.

B*A*R*B*E*D

can any one explain why you cant use this work

 

I used a brass B*A*R*B*E*D "splice" fitting... drilled the hole out a LITTLE to make it fit to the first barb, then used a TON on epoxy sticks to make a new tray around it to support it...

 

I used a plastic ****** yard sprinkler system part (black abs in the sprinkler section at Lowes or wherever) and used a two part plastic epoxy. File and trim where needed then glue...

 

I used a 3/8" plastic b_a_r_b_e_d tee. Cut off one of the braches, drilled out the hole in the drip pan for the fitting to side into and glued it in place with Devcon Plastic Welder.

There is an article in the May 14 issue of Land Rover Monthly that cover removing the headliner, repairing the drain line and resealing the sunroof the the body.