Presently working on makeing repair kits for Disco1 & 2 sunroofs. I have found the defect components and have a solution. I make things out of plastic. I have molds ready to replace the rollers and slides, along with the plastic piece that connects to the main gear spring. If you have a broken part, you can mail the parts to me and I will either re-mold a new stronger plastc piece to it or cast you a new and stronger part. Right now I'm working on the master for the roller chassis part. This part currently is made of composite metal. I'm makeing it stronger so it will not bend and break. If you have a broken or non working sunroof it is probably because the roller chassis bent/broke or the plastic piece on the gear spring broke off. My kit, which will be available here and on Ebay will be available in another week. Until then, if you have broken parts and your roller chassis is not damaged. I can replace your parts with new or re-molded parts. Pm me for more details.

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I now have certain parts available to repair sunroofs. If you have broken/bent parts, PM me for details. Let's get them working again.

 

Thank you, first of all. The only parts on my sunroofs that have failed are the gaskets but when (not if) the other components fail I'll be sure to contact you (bookmarked)

 

This is how sunroof repairs will have to work. Every sunroof has two 30 inch springs inside as a component that acts as the gear to move the window open and closed. Unfortunetly this spring is not easily obtained. Larger business's want me to place an order of hundreds with a contract. I do not think so. The spring is one of the major failing components. Attached to the spring is a plastic catch that inserts into the roller chassis. This roller chassis is what controls the function of pushing or pulling a few other components to open and close the glass. The plastic end of the spring is molded on. Which means I will need everyones old springs sent to me in order to replace the plastic catch with a new stronger piece. All the other components can go into a bag as a kit. Again, if your springs have broken plastic catch's they will have to be sent to me for repair. I'm ready to get your sunroofs working again. PM me for details. Parts are cheap. I can sell them all together or seperately based on your sunroof needs.
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My front sunroof works fine, but it rattles like crazy over bumps. I have not had time to get up and look it over yet - is there a common part that breaks that causes this? I can push up on it from inside and it goes up about 1/8 to 1/4 inch, mostly on the passenger side. I am just not sure what may be loose or broken yet, but since you are in the sunroof repair business maybe you know??

 

Your roller chassis is bent and dislocated from the window frame mount. This roller chassis is made of composite metal. Once bent it will never work. It will eventually snap in half. This is a common defect. Next if it has not happened yet. The 30 inch spring which is used as the gear for moveing the window up and down will fail. There is a small piece of plastic known as the catch molded to the spring. This catch connects to the roller chassis and moves the roller chassis to actuate other components. This plastic catch is probably already starting to tear away from the spring. When it does, you will loose all movement. I have made a new roller chassis which is stronger and made a bit thicker to handle the stress and abuse. To check your damage you will need to remove your headboard. Remove 3 #20 torque bolts from the motor. Remove 14 #20 torque bolts from the under cover and remove 4 phillips screw from the glass and glass mount. Then remove 4 phillips screws from each side rail. Remove each rail and inspect for damage. I can replace everything except the rail, gear springs, glass mounts. I can fix the spring gears and mold new plastic pieces to them. First you need to find out what all was damaged.

 

When you say drop the headboard, you mean take out the entire headliner?

If so, then I may as well plan on a long weekend (or more) of stripping that down too since some edges are starting to pull apart. I guess it would make sense to take the rear sunroof apart as well at that point......Are the 2 sunroof identical in all the components?

 

Now that's initiative! Thanks D2&ME, great stuff. Bookmarked as well.

 

90 percent of those fail because the motor or the guides. Unless you get something stuck in it then it will break. Only on a freelander or a lr3 does the guides completely break or start to fail and crack leading to intermittent failure of the sunroof. And even then on an LR3 the part that cracks just acts up in the heat. The sunroof just stops working until its repgmed and then it works fine.


How about designing a new window kit to fix all the regulators including the rear regulator on a freelander as they all fail and the windows come down.

Then sell the things to Atlantic british.


or how about some new secondary air manifold hoses since most first timers break the brass hoses the first time they try to take them off without the right equipment.

 

I'm bringing this thread back to life. Hey LRD2, my sunroof all of the sudden is slow as all-get-out. I had a "race" between the front and back and the back one was completely finished about three seconds faster. They usually go together...any ideas? Sounds like a dying motor to me