My '87 300TD's sunroof has me stumped. After all of my service to it I have to suspect there is a problem with the gear and cable mating properly so one is likely worn. Rails/slides have been cleaned and properly lubed with MB slide grease. Removed the cable, cleaned it and lubricated it.

Roof will operate depending on how I adjust the clutch nut but goes between slow and just slipping. That depends on the slightest of adjustments to the clutch nut. Too tight and it just clicks. Too loose and it runs w/o moving the roof. Just when I think I have it adjusted about correctly it will slow down and then stop or slip. It will only seal the opening shut, lift to a tilt and return to a closed position with some help from my hand.

Last year, while working on it, I smoked the motor. I mean smoke was rolling from it.

I can use some experienced advice.
Thanks
Steve

__________________
Steve
'87 300TD - 132K - Soon 4-Sale
'84 300D Turbo - 122K - Driving
'77 VW Type II - 77K - Restored
'08 250EX Ninja
English Bulldog (Brier) - My best friend. Passed away 12/02/04 while in my arms.

Still plugging away on solving this one. Today I again removed the cable and worked it in and out. On the first full removal there was a piece of fiber, similar to felt, embedded within the portion that engages with the gear. I notice there are a couple of spots along the travel path where the cable hangs up. Does anyone know if the entire length of the tube has a relief slot for the cable attachment pin (forward end of the cable) or does it close?
Thanks
Steve

__________________
Steve
'87 300TD - 132K - Soon 4-Sale
'84 300D Turbo - 122K - Driving
'77 VW Type II - 77K - Restored
'08 250EX Ninja
English Bulldog (Brier) - My best friend. Passed away 12/02/04 while in my arms.

If you disconnect the roof from the cable and move it around by hand, does it slide easily? That should give an indication of whether it's friction in the roof (i.e. the angles and fuzzy nylon sliders) or with the motor. Did you grease the lifting angles and the sliders, or just the stainless steel rails? Does the cable pull out and go back in easily? If all those are smooth and well lubed, I would look at the motor.

You know . . . sometimes the most obvious for some reason, is the most elusive. Great idea. I have spent so much time moving the cable in and out of its housing I never thought about moving the roof manually.

I still would like to know if the cable housing has the slot end-to-end or just in the area where the cable pin runs. When I read a couple threads where liquid solvents were used, I could just imagine the seepage onto the headliner . . .

__________________
Steve
'87 300TD - 132K - Soon 4-Sale
'84 300D Turbo - 122K - Driving
'77 VW Type II - 77K - Restored
'08 250EX Ninja
English Bulldog (Brier) - My best friend. Passed away 12/02/04 while in my arms.

I *think* the slot only runs part way back into the cable housing. Most of it is completely closed.

My recollection is that the cable should slide through its range of motion with almost no friction at all. All the effort is in the sunroof mechanism. A surprsingly stout amount of effort is required to operate the sunroof. You should be able to do it with one hand, and a moderate amount of push.

- JimY

JCYUHN is correct, the slot only runs part way back into the cable housing. Most of it is completely closed. I had a problem with the cable binding in the tube due to a worn plastic bushing, the cable and motor gears were replaced with parts found on ebay. Good luck.