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SUNROOF REMOVAL

R

rogerc84

New member
Anyone got experience in the early type of electric sunroof mechanism on a 1984 924?( Long guide rail at rear with limit switches on the end) Although the roof goes up and down happily enough it doesn't retract the arms to allow roof removal.After consulting Clarks Garage website I dismantled the complete mechanism. I found all components work individually and sufficiently to allow up and down operation, but once the roof is closed the plastic plate, or dog, on the end of the cable doesn't reach the limit switches to operate them . Neither does the furthest adjustment forward of the limit switches allow them to meet the dog.Hence it doesn't create the electrical configuration for the roof switch to retract the arms.
Any simple reason why the dog stops short? All very puzzling. For the moment, summer motoring will entail roof open but not removed.
 
Check to see if the roof is retracting into the bodyshell fully. Porsche are better engineers than to produce a mechanism that can't reach it's limit switch on full adjustment. Mind how you go, because the wheel inside the wheel-box is nylon, and in appearance very similar to the one on the electric window mechanism, and we know how easily they strip.
 
I agree with you about Porsche's engineers, which is why the condition is puzzling.
However you have a point about the roof panel. It does stop slightly proud of the roof surround. Originally I put this down to the fitment by a previous owner of the wrong roof seal ( from the post-86 cars), which is a tiny bit thicker than the earlier one. I have now fitted the proper roof seal and tried to bed it in, but the roof panel still doesn't close completely flush.
Its limit is accompanied by what I now think is the chatter of the drive cog on the cable 'rack', which is the signal to stop pushing the switch.
I'll enlist the help of the Associate Member of the house and see if we can persuade the roof to drop lower and the cable to run slightly further backwards. Even if it doesn't solve the matter, it might offer some info to suggest a further line of enquiry.
 
If it clicks the gear has stripped, and it makes a noise just like an electric window that closes but not tight. Experimentally you might open the wheel box and try to match the wheel to one from a window lifting mechanism, you never know your luck, but failing that, I dont have a solution other than to replace the whole lifting motor, if it's still available, as the PET catalogue does not itemise the components in the wheel box separately. FYI I mentioned the presence of some kind of microswitch in another of my post somewhere, I'm sure.(if I didn't I meant to ) Sure enough there is one, and again the PET shows it to be connected into the centre bearing of the leading edge of the sunroof.
 
you should be able to adjust the closure of the roof just by resetting the height of the two 'pushers' (sorry, my mind's gone blank as to the correct terminology!) - there's an allen bolt to adjust on each one.

have you checked thoroughly that everything is still visually okay around the motor? The casing of the wormdrive should be securely latched to the motor via two brass-coloured retaining knobs (you have to crane your neck a bit to even see them); it may be that the front one of these has snapped off, which could explain the slipping/chattering when you're trying to close the roof. If you get someone else to operate the roof while you stand at the back watching you'll be able to tell if this is the problem. I'm basing this all on your reference to 'chatter' and assuming this noise is coming from the back of the car rather than above your head? If not please ignore! [&:]

IIRC, as well as the microswitches at the back (2?) there is one located inside each 'pusher' in addition to the one at the front of the roof. If you need to know what each of these does I can post this info.... need to get on with some work now! [:D]

Oh, to recalibrate the positioning of the wormdrive, disassemble the mechanism when the arms are in the closed position (you would do this after adjusting the heights, to get a tight fit). Then without adjusting the height of the arms, take out the cogs and you should be able to freely move the wormdrive - pull it back until you reach the microswitches. Just don't pull back to far, as that causes its own problems.

if you need any further info, or if pics would help please me know. hope this helps - if not, can you give any more info that would help us narrow this one down?
 
Both of your contributions are welcome - this is not an easy problem for a forum thread to solve, as there are so many variables and significant adjustments to consider.
However - the motor and the wormdrive assembly ( the 'transfer box') seem to be all OK. I have opened the wheel box and nothing is damaged. It was all re-assembled successfully and the roof goes up and down happily enough. There is indeed a micro-switch in the front centre assembly, but I understand it is fitted between the sunvisors and is activated by the central 'hook' on the front of the roof panel as it engages. When the roof opens the 'hook' moves and allows the microswitch to operate 'off'. That's what stops the roof in the open position( According to the explanation on the Clarks Garage website). That's working OK.
The 'chattering' does indeed come from the back. I haven't gone back to investigate close up yet, but I reckon it is the wormdrive 'cog' chattering on the cable worm coil once the roof reaches a 'closed' limit defined by the pressure of the roof panel trying to fit into the space. One of the rear limit switches should be operated here to stop the motor,leaving the roof in the closed position. However, this is where the 'dog' or plate on the end of the cable is stopping short of the limit switches, so the motor is not being turned off. Hence the chattering.
I haven't read before about the adjustment of the two operating arms. I presume the allen bolt adjuster is in the roof-mounted mechanism underneath the headlining( Now do I really want to embark on that one...!)
When I had the rear assembly fully dismantled I did attempt to pull the cable back, though it didn't move. Maybe I will try again.
I will go back and re-check on the points you have both raised - unfortunately my proper job will steal me for a while now, so unless someone at the R15 meeting tomorrow night comes up with a very simple solution, I will have to postpone detailed re-investigation.
Thanks again - once I have had chance to re-visit the miscreant I will post any significant update.
 
ORIGINAL: rogerc84

I presume the allen bolt adjuster is in the roof-mounted mechanism underneath the headlining( Now do I really want to embark on that one...!)
Click to expand...

yes there is a single allen bolt securing each operating arm housing to the roof. Go on, you know you want to! [:D]

edited for typo
 
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