Body - Sunroof Seized or Jammed
No: 76/12/05/NASReplaces: 76/21/03/NAS
76/06/04/NAS
*Issue: 2
Date: 13 March 2006*
Jammed Sunroof Mechanism Repairs
AFFECTED VEHICLE RANGE:
Freelander (LN) - Five-door
up to 3A282392
Note:
Issue 2 changes are highlighted with asterisks or a grey background.*
SITUATION:
SEIZED OR JAMMED SUNROOF
The customer may complain that the sunroof on a five door Freelander has seized during opening or closing. A seized sunroof may be caused by one of the following:
^ The left hand or right hand sunroof pivot block may be broken where the wind deflector hooks under the moulding.
^ The left hand or right hand sunroof rear drive slide may be broken where the drive cable attaches to the plastic runner in the rail.
^ The drive gear in the motor is damaged, worn or stripped because of a jammed slide.
RESOLUTION:
REPLACE DAMAGED SUNROOF COMPONENTS
Upon verification of the customer complaint, replace either the left hand or right hand pivot block or the left hand or right hand rear drive slide.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
INSPECT AND REPLACE DAMAGED COMPONENTS
1. Open the sunroof glass.
2. Inspect for a broken left hand or right hand sunroof pivot block
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN Freelander/2004 > Workshop Manuals > Service Procedures > Bookmark "SUNROOF/REPAIRS" > "Drive cables & slide assemblies - sun/ sliding roof - front - 5 door" link
3. Refer to GTR section 76.84.09 for 5-door sunroofs and remove left hand or right hand sunroof mechanism. (Figure 1)
4. If inspection does not reveal a broken left hand or right hand sunroof pivot block replace the broken left hand or right hand sunroof slide mechanism following repair procedure in section 76.84.09.
5. If a pivot block is broken, remove the worn pivot blocks as follows:
^ Position the sunroof slide assembly in maximum tilt position.
^ Remove the Torx screw securing the link arm to the slide assembly and release the arm. (Figure 2)
NOTE:
As the upper nylon rack with the timing mark is moved forward, the lower "unmarked" slide will move to the rear.
^ Slide the upper nylon rack with the timing mark (Arrow "1" in Figure 3) towards front of the slide assembly until unmarked nylon rack reaches a fully rearward position.
^ Press the unmarked nylon rack through the opening in the back of the slide to hold it in position. (Arrow "2" in Figure 3)
^ Slide the marked nylon rack towards the front of the slide assembly and remove.
^ Slide the lower unmarked nylon rack forward past the gear and remove. (Arrow "3" in Figure 3)
^ Remove the nylon gear. (Figure 4)
^ Check the racks and nylon gear for wear and obtain a new track assembly if the components are worn.
^ Slide the upper slide assembly backwards and release it from the lower slide assembly. (Figure 4)
^ Remove the sunroof cable.
^ Release the forward lever from pivot block.
^ Release the pivot block locating peg from the upper slide assembly.
^ Slide the pivot block towards the front of upper slide assembly and remove. (Figure 5)
6. Install new pivot blocks as follows:
^ Slide the new pivot block into the upper slide assembly and locate the peg into position.
^ Install the forward lever to the pivot block.
^ Install the sunroof cable to the pivot block and the lower slide assembly.
^ Slide the upper slide assembly into the lower slide assembly until maximum tilt position is achieved. (Figure 6)
^ Lubricate the unworn or new nylon gear and install to the upper slide assembly.
7. Install left hand or right hand sunroof mechanism following procedures in section 76.84.09.
TIME SUNROOF ASSEMBLY
1. Install the unmarked nylon rack from the front and move it rearward, completely past the gear.
2. Install the nylon rack with the timing mark from the front.
NOTE:
The following steps effectively engage two teeth of the "unmarked" nylon rack with the gear and realign the timing mark with the center of the gear spindle.
3. Align the slide mechanism as follows:
^ Align the timing mark on the "marked" slide with the center of the gear spindle. (Figure 7)
^ Move the marked nylon rack towards the front of the slide assembly by two teeth. (Figure 8)
^ Push the unmarked nylon rack forward towards the front of the slide assembly making contact with the gear.
^ Move the unmarked slide forward until the timing mark on "marked" slide is again aligned with centre of the gear spindle. (Figure 9)
4. Align the link arm mounting hole to the slide assembly and start the Torx screw. (Figure 10)
5. Tighten the Torx screw to 3 Nm (26 lbf.in).
6. Refer to GTR section 76.84.09 and complete installation of the sunroof drive cables and slide assemblies.
*REPLACE SUNROOF MOTOR
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN Freelander/2004 > Workshop Manuals > Service Procedures > Bookmark "SUNROOF/REPAIRS" > "Drive cables & slide assemblies - sun/ sliding roof - front - 5 door" link
1. If a ratcheting noise is heard when the sunroof is operated, refer to GTR section 76.84.07 and install a new sunroof motor assembly to repair the damaged drive gear.*
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