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Old 08-03-2011, 03:34 PM
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Join Date: Aug 2009
Location: Seattle
Posts: 354
It turns out my fiber gear is worn down. I didn't realize it at first, but after a bit more research the teeth on the fiber gear are apparently not supposed to be concave.
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Old 05-20-2012, 06:32 AM
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Join Date: May 2012
Posts: 5
I have the same sort of issue but worse and need help!

I have a 86 190 e and the motor has been removed and the cable is loose. But the sunroof panel only opens 2/3 of the way and can't get to the bracket that hold the cable in the front so I can pull the cable from front. I tried to see if I could remove the lining in the read passenger side but it looks like some upholstery glued to the roof...very frustrating. My question 1- is how do I know whether the sunroof track is stuck or whether the cable is holding it from moving? When I pull the cable from trunk the sunroof moves back but won't move forward by any means including extreme force.

2- If I have to saw off the bracket, do you think I can get the cable out considering my situation?

I appreciate any help

Originally Posted by 86-300sdl View Post
Two or three conditions are probably at play. At minimum you will need a new cable cause the cable is toast. Even if the motor gear teeth are stripped the cable winding will be shot

1) The cable winding on the cable is stripped so the gears can't grab it.
2) If the winding is chewed up much at all it won't feed up through the cable tube to pull it out from inside the car.
3) Sunroof motor gears are stripped & or the clutch drive is stripped.

Bottom line you will probably have to cut the cable.

Going forward remember to not force pull the cable too hard or you bend the tube and it all must be replaced...

Eventually you will have to open up the sunroof motor to get at the frayed cable. And Eventually you will need to cut off one section (end) of the cable so it will cleanly pass through the tube. Choice is while it is in the car or out of the car.

Cutting the cable must be precise & clean. Wire or cable cutters probably will leave a burr or tail of some sort that won't pass the tube. I used a dremel with a very fine steel cutting blade. You could use a similar blade on a drill.

So here is your fix...Get your cutting rig hooked up and go the the cab of the car. Cut the sunroof cable mount flange/connector off of the cable. I repeat be very precise...go slow. Now that you have a clean cable end go the the trunk and unbolt the motor from the trunk mount. Unclipp the retaining clip holding the tube to it so the motor is somewhat free of the tube. Now while you are trying to hold the tube so it won't kink at an upper bend, have someone grab the motor and start pulling the cable out of the car to the rear.

Or you could cut the cable rear of the tube via opening the motor up while inside the trunk by removing the nut on the emergency crank spindle to find a clean upper section of cable ....but there is a lot more room in the cab.

Reinstall is simple. Once the assemblies are back in place feed in the cable from the interior of the car...and you already know the rest
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