Sunroof - Rattling Noise When Partially/Fully Raised

Article No.
00-9-3

DATE
5/1/00

TITLE
NOISE - "RATTLING" HEARD FROM SUNROOF WHEN ROOF IS PARTIALLY OR FULLY RAISED - VEHICLES BUILT THROUGH 6/15/1999

MERCURY
1999 COUGAR

ISSUE
A "rattling" noise from the sunroof guide shoes when the roof is partially/fully raised to the vent or open position may be heard on some vehicles. This may be due to the hardness of the material used for the existing guide shoe.

ACTION
Replace sunroof guide shoes with revised parts made of a softer material. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

1. Open the sunroof approximately halfway (rearward).

2. Remove the interior trim panel from the sunroof panel by:

a. Carefully pulling downward on the front edge of the trim panel to disengage the three (3) retaining clips.

b. Slide the trim panel forward approximately 25 mm (1") to disengage the rear retention brackets.

c. Remove the trim panel from the vehicle by moving it rearward through the sunroof opening.

3. Move the sunroof panel forward until it is in the raised (vent) position.

4. Pull the sunroof opening trim moulding off of the sides (only) of the headliner.

5. Remove the four (4) screws which attach the sunroof panel to the sides of the panel frame.

6. Lift off the sunroof panel.

7. Lightly pull outward on the slider arms to separate them from the guide slots..

8. Pull off the existing plastic guide shoe attached to the guide pin at the end of each arm and replace it with the revised Slide Assembly (F8RZ-63502M78-AA).

9. Lubricate the guide shoe with Krytox grease 164-R4906 (available in Rotunda 164-R4900 Squeak and Rattle Kit).

10. Reinstall the new guide shoe/arm into the guide slots.

11. Reinstall the roof panel, tightening the four (4) attachment screws enough to hold the sunroof panel snugly, yet still allowing movement.

12. Close the sunroof and adjust the panel to a height of 1 mm below the roof panel at the front edge, and 1 mm above the roof panel at the rear edge.

13. Raise the sunroof to the vent position and torque the four (4) roof panel attachment screws to 3 N.m (27 lb-in).

14. Reinstall the sunroof interior trim panel by reversing the procedure in Step 2.

15. Reinstall the sunroof opening trim moulding.





PARTS NO





WARRANTY

DEALER CODING

CONDITION
BASIC PART NO. CODE
63502M78 33

OASIS CODES: 102000, 105000, 702300