What are ya'll using to re-seal the sunroof pans? After 3 hours I almost have the complete headliner out. I have tons of water that collects on the upper console when it rains.

 

I used Permatex "The Right Stuff" black gasket maker for the little plastic corner pieces. Has been great for years now. I remember it being a fussy job. There is a raised level going from the tray to the plastic corners. I made sure of a smooth transition and no water paths. I was not keen on the design (Thanks Webasto!)

When you look at the design of the sunroof you will find that there are drains only on the front. If you park with the front of the truck up the sunroof leaks. I always try to park level or downhill.

Disco's can travel over rough terrain, but need to be parked flat!

 

Marine silicon or just plain silicon.

 

https://www.permatex.com/products/ga...-gasket-maker/

Automotive Silicon

Fast drying. The corner pieces are not captured well so movement after fitting would be a problem.

 

Tube of GE silicon from Home Depot

 

Strongly recommend you go polyurethane/urethane, not silicone.

I used (after research and recommendation from others) Sikaflex 221 to seal the plastic top frame to the roof. It's both a sealant, and an adhesive. Sikaflex 291 is the same thing (basically) but for marine use. Both come in a few colors, black/white/grey etc.

A little goes a long way.

(EDIT: I also used the same to seal the little plastic corner trays, and elsewhere on the sunroofs that needed a dab)

 

Sikaflex makes great stuff - curious though why you specifically don't recommend silicone. I don't see a problem with it, but might be missing something.

 

Just got done with the water hose. The pan is sealed up with no leaks. The plastic hose drain connectors leak on both sides. Do these come off?

 

I sealed the sunroof to the roof with 3M Butyl Strip Caulk - 08578

I followed another post on this forum for redoing the broken drain tube plastic nipple. Basically, get rid of the plastic nipped all together by cutting it flush with the black plastic corner piece. Find a piece of metal tube that will fit the rubber hose - 2" length. Drill a hole in the black plastic corner piece where you cut the plastic nipple off - the hole should be as tight a fit as possible for the piece of metal tube. Stick the tube in the corner piece and JB weld them together. JB weld the corner piece to the sunroof frame. I took it a couple of steps further by RTVing over the JB weld and then spraying it all with FlexSeal. All 4 drains (front and rear). Dry as a bone.

 

Thanks everyone! So either way I have to take out the pan to reseal the plastic corners or can you take the corners off with the pan installed?