Sunroof - Glass Shudder During Operation
NUMBER: 23-029-01GROUP: Body
DATE: Oct. 12, 2001
SUBJECT:
Sunroof Shudder
OVERVIEW:
This bulletin supplements the service manual and provides detailed sunroof repair procedures for sunroof opening/closing conditions.
MODELS:
2001 - 2002 (ST) Sebring/Stratus Coupe
NOTE:
THE INFORMATION THAT RELATES TO SUNROOF SHUDDER APPLIES TO ALL 2001 MODELS AND 2002 MODELS BUILT PRIOR TO JULY 16, 2001 (MDH0716XX).
SYMPTOM/CONDITION:
Some sunroof equipped vehicles may exhibit sunroof glass shudder when the glass is opening or other conditions where the glass will not fully close, will not close, or closes then reopens.
DIAGNOSIS:
Verify the condition by operating the sunroof. If the sunroof will not close properly, perform in-vehicle re-timing procedures. If the glass shudders when opening, perform in vehicle re-timing and evaluate its effectiveness. If the sunroof glass continues to shudder when opening, perform the disassembly/repair procedures.
For reference, the sunroof should operate smoothly in the following manner:
NOTE:
THE SUNROOF INCLUDES AN ANTI-TRAP FEATURE THAT WILL STOP AND REVERSE THE CLOSING PROCESS IF AN OBSTRUCTION IS CONTACTED THE ANTI-TRAP FEATURE IS DISABLED WITHIN THE LAST 30 MM (1 IN) OF TRAVEL.
NOTE:
IF ANTI-TRAP IS SENSED 5 TIMES WITHIN THE SAME KEY CYCLE, OR POWER TO THE SUNROOF MODULE IS INTERRUPTED WHILE THE SUNROOF IS OPEN (IOD FUSE, BATTERY CABLE, DEDICATED FUSE, ETC.), THE SUNROOF WILL NOT CLOSE PROPERLY. IN THIS CASE, THE ROOF WILL ONLY MOVE 30 MM (1 IN) THEN STOP EACH TIME THE SWITCH IS PUSHED FORWARD. IF THIS OCCURS, REPEAT PUSHING THE SWITCH UNTIL THE SUNROOF FULLY CLOSES. ONCE THE SUNROOF CLOSES, IT WILL RELEARN THE STOPS AND OPERATE PROPERLY.
PARTS REQUIRED
REPAIR PROCEDURE
In Vehicle Re-Timing
1. With the sunroof in the open position, press the switch forward to close the sunroof.
2. When the sunroof reaches the fully closed position, continue holding the switch in the closed direction for 20 seconds. This operation resets the sunroof stop.
3. Open and close the sunroof to verify smooth uninterrupted operation. If sunroof glass shudder remains during the opening cycle, continue with the repair procedure.
Sunroof Disassembly (Fig. 1)
1. Make sure the sunroof is in the fully closed position and remove the glass.
2. Verify that the sunroof was in the fully closed position by inspecting the basic location of the mechanical timing marks located on the right and left slide assembly (Fig. 2). The inner single mark should be between the two forward outer marks.
3. Remove sunroof from vehicle following the Sebring/Stratus Coupe service manual volume 3 p/n 81-270-1020 (2001) page 23A-46 or 81-270-02033 (2002) page 23A-48.
4. Place the sunroof upside down on a bench.
NOTE:
PROTECT THE SUNROOF ON THE BENCH BY PLACING IT ON FENDER COVERS.
5. Remove the motor from the housing (2 bolts).
NOTE:
ONLY REMOVE THE MOTOR WHEN THE SUNROOF IS IN THE FULLY CLOSED POSITION. IF MOTOR REMOVAL OCCURS WITH THE ROOF OPEN, SYSTEM TIMING WILL BE DISRUPTED. IF THIS OCCURS, SEE MANUAL MOTOR RETIMING AT THE END OF THIS PROCEDURE.
6. Flip the sunroof over to in-vehicle position on the bench.
7. Remove the drip channel screws (2) and drip channel, rear guide rail screws/stoppers (2), and sunshade stoppers (2) (Fig. 3).
NOTE:
INSPECT THE SUNSHADE STOPPER HOLES AND RAIL ENDS FOR ANY BURRS. REMOVE BURRS AND/OR STRAIGHTEN THE RAIL ENDS BEFORE REMOVING SUNSHADE TO PREVENT TEARING THE SUNSHADE CLOTH.
8. Remove the front and rear sunshades as a set by sliding them rearward and out of their channels. Pay attention to the orientation of the front and rear shade for reinstallation.
9. Move the right and left slide assemblies rearward by placing a screwdriver between the steel bracket and guide located in front of the mechanical timing marks. Pull the mechanism rearward. The slide assembly will move rearward and begin to tilt up (Fig. 4).
10. By hand, pull rearward on the tab located at the rear of each tilted slide assembly. Continue pulling rearward on the tab until both slide assemblies are in the fully tilted up position (Fig. 5).
11. Gently twist each slide assembly inward so the pin (located at the front of the assembly) will clear the front stopper (Fig. 11). Pull rearward on the assembly and slide each one out until the drive cable attachment can be seen. Disconnect the cable from each assembly (Fig. 6).
NOTE:
THE CABLES DO NOT REQUIRE COMPLETE REMOVAL OR REPLACEMENT. IF THE CABLES ARE REPLACED, MAKE SURE THEY ARE LUBRICATED WITH SUNROOF GREASE PRIOR TO INSTALLATION.
12. Continue pulling each slide assembly rearward until the assembly is removed from the track. Discard the old slide assemblies.
NOTE:
PAY ATTENTION TO THE TWO REMOVABLE GUIDE BLOCKS (WHITE IN COLOR) ON THE ASSEMBLIES AND NOTE THEIR LOCATION FOR INSTALLATION ON THE NEW SLIDE ASSEMBLIES (Fig. 7).
13. Clean the old grease from both sides of the sunroof track channels with a clean dry cloth or shop towel (Fig. 8).
NOTE:
DO NOT USE SOLVENT TO CLEAN THE TRACK.
14. Apply a small bead (approximately 1/16 inch diameter) of sunroof grease p/n 05083160AA to six surfaces on both sides of the sunroof track channels as shown (Fig. 9). Apply the grease to the full length of each location. Approximately 2.5 ounces of grease will be used to lubricate the sunroof. If necessary, a clean flux brush (or equivalent) can be used to distribute the grease p/n 05083160AA in the proper locations.
NOTE:
DO NOT USE ANY OTHER TYPE OF GREASE. OTHER TYPES OF GREASE CAN CAUSE SUNROOF SHUDDER.
15. Obtain the new slide assemblies p/n MR987384 (right) and MR987383 (left). Apply sunroof grease p/n 050831 6OAA to each of the 3 permanently attached shoes. Apply the lubricant to the surfaces that will come into contact with the sunroof channel.
16. Apply grease p/n 05083160AA to the guide blocks (white in color) and install them on the slide assemblies. The short block attaches to a pin on the outboard side and the long block attaches to two pins on the inboard side with the hook end facing toward the rear of the assembly.
17. Hold the guide blocks in position and insert the slide assembly into the sunroof channel by first inserting the longer block and then the shorter block into the channel (Fig. 10).
NOTE:
DUE TO TIGHT CLEARANCE, THE ASSEMBLY WILL BE DIFFICULT TO INSERT INTO THE CHANNEL. CAREFULLY WORK THE ASSEMBLY INTO THE CHANNEL.
18. Push the assembly part way into the channel and attach the cable (Fig. 6).
19. Cycle each assembly front to rear 5 or 6 times by hand to distribute the grease.
20. By hand, push the slide assembly all the way forward then push forward on the tab located near the rear edge of the assembly (Fig. 5). Push the tab until the tilt mechanism closes. Make sure the tab locates itself into the slot in the channel.
NOTE:
MAKE SURE THE STOPPER PIN LOCATES ITSELF IN FRONT OF THE STOPPER BLOCK (Fig. 11).
21. Using a flat blade screwdriver, push forward on the rear shoe until each assembly is pushed to the forward most position (Fig. 12).
NOTE:
MAKE SURE THE ASSEMBLIES ARE PUSHED ALL THE WAY FORWARD BEFORE PROCEEDING WITH MECHANICAL TIMING ADJUSTMENT.
22. Adjust the mechanical timing by inserting screwdriver in front of the timing mark location and pushing the inner mechanism rearward until the marks are aligned. The preferred location is with the single inner mark aligning with the second outer mark from the front (Fig. 13). Make sure both sides are aligned to the same position.
23. Install the motor by gently rocking it while inserting the screws. Tighten the motor bolts to 5.4 +/- 1.5 Nm (4 ft lbs +/- 1 ft lb).
24. Clean any grease from your hands and install the sunshade.
NOTE:
CAREFULLY INSERT THE SUNSHADE TO PREVENT DAMAGING THE CLOTH ON THE EDGES OF THE TRACK.
25. Install the sunshade channel stoppers and tighten the screws to 1.4 +/- 0.3 Nm (1 ft lb +/- 1/4 ft lb).
26. Install the rear guide rail stoppers and screws. Tighten the screws to 1.4 +/- 0.3 Nm (1 ft lb +/- 1/4 ft lb).
27. Install the drip channel and tighten the screws to 1.4 +/- 0.3 Nm (1 ft lb +/- 1/4 ft lb).
28. Reinstall the sunroof assembly into the roof.
Manual Motor Retiming
This procedure is only required it the motor was accidentally removed from the sunroof while the roof was open.
1. Hold the motor assembly in your hand and connect it to the body harness.
2. Cycle the sunroof switch rearward (open position) and hold until the motor stops moving.
3. Cycle the sunroof switch forward (close position) and hold until the motor stops moving.
4. The motor can now be reinstalled into the roof after mechanical timing as described above is performed.
POLICY
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE