i've already taken everything apart i can get to so far. the headliner and the sheetmetal roof itself are off. the roof appears to slide fine along the tracks. the clip that connects the crossmember (in the roof) to the cable is fine. the dash switch and motor seem to work fine. i think the problem is the cable is damaged. how do it remove the motor and gearbox from the cablle guide? i want to be able to isolate the cable to be certain that it's not the gearbox. i already took off the cover to the gearbox but can't find out how to remove the gear itself, so i can remove the cable. the symptom is that the roof only moves about 20mm when i try to open and close it with the dash switch. when i tried to use the plastic emergency nut in the trunk to move the sunroof, it wouldn't turn and i ended up breaking the nut, as it was already cracked and worn.

any help will be appreciated.

thanks

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dew
86' 190e 2.3L 16v

jasondew,

To get the cable out, you disconnect the clip from the crossmember of the moving roof panel, and then push the button to make the roof shut. The cable will be ejected out the tube into the car area further than it normally goes (the sunroof end of travel usually stops the cable), and then you can pull it out by hand. You get it back in by doing the reverse, you push it all the way back in, then I went and turned the operating nut on the motor to draw the threaded end of the cable into the drive nut while my son kept pushing on the cable to get it into the tube and engage the drive nut. Once out you can check the cable for grease, debris, wear, and general condition. I put mine back in and it has worked fine since. Good luck, Jim

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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

i managed to get the cable out. i disconnected teh gold clip. like before the cable would only move about 20mm. but, if i pulled on it, it would move just a little more out each time i cycled the button. i got the cable out and took apart my gearbox. the small roller gear is busted. so, my understanding is that i have to buy an entire new motor--great.

thanks for everyone's help.

__________________
dew
86' 190e 2.3L 16v