W126 sunroof advice needed(long)

[RG5384]

When I bought the car, I was told it had voltage to the motor, and that the motor just wasn't turning. I took the motor apart, and it wasn't' turning due to a burnt off wire. I then re-soldered the wire and re-installed it. I could not get the motor to turn from the switch inside the car, so I used a 12v battery to run the motor. All I got was a grinding sound. I then went and got another motor, without the gearing as my gears seemed to be fine inside the motor(their metal). This new motor still wouldn't respond to the switch and when hooked up to the battery caused the same grinding noise. I finally was able to get the roof open manually, but freeing it up didn't seem to help any(it seemed to have been painted and not opened since). I then took it to an interior specialist place that also worked on sunroofs. They looked at it and decided that it needed some attachment pieces in the roof as well as a new cable(looks like a worm gear on one end and attaches to the moveable roof section at another). They ordered the part and replaced it. They then tried to put the motor to a 12v source(I told them I'd troubleshoot the electrical problems) and it made the same grinding noise. They then blamed it on that the motor was missing some guiderail pieces on the inside of it, and because they were missing the "worm gear cable" was being pushed too far away from the gear itself, and therefore not making enough contact. The only guiderails for the cable that I am aware of are the two outside "snap" pieces. The clutch is tightened up enough to grab, and I have tried messing with that little screw all to no avail. So after shelling out 200 bucks(parts and labor) and having no improvement, I'm at my wits end. I tried to troubleshoot the electrical system, and bought a new switch, but I still have no power in the back. The switch checks out using a continuity meter. I'm not sure if theres power at the switch so I probably should check on that. Also, the new motor has 3 wires, a red one, a green one, and a black one. My old motor had green and black. Even if you can't help me with my individual problem do you know of a good roof shop in st.pete Florida? I appreciate your help and sorry for the long post
R

[h2odiesel]

RG,

It is most likely the fiber drive gear in side the motor housing. Unmount the motor and flip it over to gain access to the side that normally faces out and remove the cover. remove the clutch nut from the other side and the metal gear, fiber gear and small channel will drop out If the fiber gear is concave on its working surface it was likely jumping over the spiral wraps on the cable. The only place I could find the gear was through Randy Steele at E.P.S. in Ca. If you are missing the small channel it looks like you'll be making another trip to Rick's, but first check in the fender well to see if it droped out unnoticed the last time someone worked on it.

Bob D.

[RG5384]

thanks, can you describe the small channel? i think i may well be missing it. I might just go get a complete motor from ricks, should be able to talk him down to about 100 bucks if i give him the other one without the gears.
thanks
R

[h2odiesel]

The channel is about 21/2 inches long (width of the case where cable goes through). It is stainless steel with a u shaped cross section wide enough to hold the cable. There are tabs at either end to locate it in the housing. If you get a used motor check the fiber gear It seems to be a wear item. Mine cost about $60.00.

Bob D.

[RG5384]

and this peice sits inside the channel already built into the housing? if so i think you just solved my problem with the mechanical part. now to figure out whats going on electrically(looking soooo forward to taking apart my console.........again.........for the 10th time.....)
thanks bob!
R

[ncarter]

Bob,

Did you get a used motor & gearbox, or a replacement fiber gear? I've been searching for a replacement fiber gear for a long time now as the rest of my sunroof system is fine, but without that gear it does nothing. I tried contacting Webasto by e-mail but got no response; they had a couple of phone numbers on their website which I may try next. I'm also considering having a machine shop just fabricate one out of steel for me (probably pricey) or trying to repair one of my damaged ones with epoxy or some of that farm-bond stuff.


RG,

If you can't find anyone at all to help you, I might be able to. I've taken my sunroof apart several times (yeah, don't ask) and am pretty familiar with it. It's in the 123 body but it's most likely the same Webasto sunroof. I also have TWO working sunroof motors - the two-cable (green & black) like you describe - but ZERO intact fiber gears, so if you need a motor I could part with one of 'em cheap.

- Nathan
'83 240D "Steiner"
'00 New Beetle TDI

[h2odiesel]

Nathan,
I got a replacement gear from Randy Steele at European parts specialists http://epsparts.mbz.org/ If you can't find it here at the Parts Shop (be sure to try them first, after all they do provide us with this great forum) Randy can get it for you at a good price. No one else had this gear. He go it to me in two days.

Bob D.