drb930

I know a lot of you out there are having major problems with your coupe sunroof's.

For those of you that just have that Grinding noise when trying to close at the end, I have some information for you.

My sunroof would work if I pushed up on the motor while trying to operate the sunroof.
Today I took the sunroof motor out to have a look see.

In the 1st picture it shows how I got the motor out, removed the dome light, sun visors, and the grab handles, the driver's door seal partial, and the top part of the driver's A-pillar cover.
The motor will come rite out then.
The 2nd, 3rd pictures show how the sunroof motor transmission gear cover is warped, and the 4th picture shows how low the gear sets in the sunroof motor transmission.
The 5th pictures shows how high the gear sets in the sunroof transmission when pushing up on the gear from the bottom.
There was about .040, or 1mm in play in the gear up and down movement.
The 6th picture shows the cover straightened, and the gear height in the sunroof motor transmission.
I believe the sunroof motor transmission gear cover is a piece of $#!t design, as the cover has no strength. The covers probably would warp after time as it is just junk pot metal, but when these sunroof's are not maintained and greased they take so much torque to open that that junk cover has no choice but to warp.

Tomorrow I plan to go to OSH Mercedes department and buy some may be 1/4" angle and weld up a frame that will use the stock cover bolt hole locations, and will bolt on top of the transmission cover with longer bolts to strengthen the cover up.
Then grease the crap out of the sunroof per the Mercedes Pano clean and lube guide and I think that I will end up with a working sunroof.

More to come-


Thanks,
Dave

SunnyRayToronto

I haven't experienced any problems with my pano, yet (knock on wood!),... saturating the whole thing with silicone lubricant spray twice a year probably helps! Yeah I'm paranoid!

Anyways,.... a simple 1/4" lock washers might help:
Credit goes to mbryant107 of another forum,... on degraded rubber grommet replaced with 1/4" lock washers
http://www.benzworld.org/forums/w203...oblem-fix.html
http://www.flickr.com/photos/2874197...th/4970032420/

drb930

My grommets are gone as well, but I am going to make bushings out of nylon.
The main problem with mine is that the warped cover is dropping the drive gear down too low.
Thanks for the post,
Dave

drb930

Today I went to OSH Mercedes department.
Picture- and bought a Electrical Cover Plate (it was cheap and already had a hole in it!), some Allen bolts, Washers, and Grommets, for a total cost of about $4.00.

Picture- I used the cover as a template and cut the plate.

Picture- Cover plate fitting.

Picture- Cover plate installed and motor ready to be re-installed in car.

Picture- Sunroof Motor re-installed in car.

Picture- Sunroof works perfectly, but I am going to do the clean and grease procedure now.

Hope this helps some of you guys out there?


Thanks,
Dave

valexv

yeah mine works when i press the motor up, i finally got it closed and leaving it like that for now

C230Brit

Thank you Dave, very insightful. What you describe appears to be exact issue I have experienced this summer. Will let post back my repairs (and if I find anything to be different).

Rich

valexv

how much would you charge to put together another package like this?

drb930

I knew that I should have made a template of the plate!
Valexy- it's not the parts that cost, but the time to make the plate.
Also your cover probably needs to be straightened as well, so would need the plate and and motor to set up the clearance on the gear.
As you are straightening the plate, you have to keep checking the clearance to take it to zero, but not too tight.
The plate then just holds the cover in the proper place without allowing the factory cover to flex.

Thanks,
Dave

SeaCoupe

This is an exciting fix! I had never thought of it. However, I think the motor gets this way for a reason. Likely having to overwork to close the

Definetly make a template! Did you cut it out with Tin snips?

Hey, if you do this again, would you allow me to help? I'm in Gardena, and would pretty much drive anywhere. Or you could be the "instructor in a hosted Coupe Sunroof day at my warehouse.

Ed

drb930

I thought it was a pretty exciting fix also.

IMHO these motor covers will warp no matter what, it is just such a thin piece of junk cover. If you really look at how it is designed you will be able to see why it warps the way it does because of the one side just has no support where the cover passes over the worm gear.

My sunroof works perfectly now, even before I re-greased the whole thing.

These sunroofs take a lot of torque to open even in the best of conditions. If they have been neglected, or need repair it is putting even more stress on the system.

One thing to think about is the fact that the worm gear in the sunroof transmission motor is steel turning against a plastic gear that is then transferring the torque to a steel gear that is meshing with the steel gear teeth of the sunroof cables that actually move the roof panel. If there is a weak point in the gears, it's going to be at the steel motor worm drive against the plastic gear.

The cover plate is too thick to cut with tin snips, I used a cut-off wheel on my die grinder.
I did not make a template, but you don't need one, just use the cover as a template.

I don't plan on doing it again, because with that plate on top of the factory cover, this thing will never warp again!

If you want me to come down and do a show and tell, I would be happy to help you guys out at your warehouse.

Thanks,
Dave

valexv

i live to far, if you guys do this you should make some extras, at least one for me

drb930

Valexv- If we do this, I will definitely make one for you!

altafwahid

I think I have the exact same problem. I noticed my motor keeps jumping when I try to open and close the sunroof (which won't open or close anymore). I'm in Anaheim, if you do make another one, please make me one too!

But I might attempt this myself, can I ask how you cut the metal?

drb930

Cutoff wheel on a die grinder.
But you could use a hacksaw if you don't have a cutoff wheel.

jazamm42

I've this problem I seem to be unable to get off the rearview mirror and get the front of the headliner loose. I removed Left A-pillar cover and all the trimmings and i need help with headliner clips and mirror

drb930

The mirror should just pull-off.
You need to remove the drivers door seal, grab handles, that holds up part of the headliner.

These pdf files should help you-

Thanks,
Dave

C230 Sport Coup

OSH? Is that the name of the Mercedes dealer?
ha.
Nice fix. Didn't see this 1st time around.
I did read another thread where someone used some washers on the bolt.
This looks like a better way to go.
I haven't experienced problems.....yet. But then my pano was replaced under warranty....twice. Note the wind buffer piece on my 2002.
You can DL the Mercedes Pano clean and lube guide here FYI for thread continuity.
And some other far out and groovy coupe files like the original 2001 Euro brochure.

I need some of the approved sunroof grease if someone can spare a little.
I'll send you a bit of Krytox in exchange which is the very expensive liquid lube specified in the documentation, you put the drops on the rear rails.
Don't need much.

A film canister would do nicely since the grease comes in a huge tub.
Bueller? Bueller?

drb930

Todd,

I went to Encino MB with a film canister, and the parts guy just filled it up for me.
Said he goes through about 5 cans a month.

Thanks,
Dave

jazamm42

Thanks Dave ! I seem to have pulled and pulled but it hasn't released. What's the trick?

jazamm42

got it ! thanks ! what a community of Benz owners! should have looked @ the second pdf before my response, puts a damper on my warm fuzzy feeling

drb930

When you get the motor out, and the cover off, check the cover with a straight edge, it will be bowed.
Carefully straighten it, I used a large socket on the bottom of the cover to support the outside edge part and a smaller socket on the top side with a mallet to gently straighten the cover.
It is made of pot metal, so be careful.
Work the cover a little, and then keep checking it on the motor until you see that if is flush all the way around the cover and motor meeting flange.
Make your reinforcing plate, and put it all back in.
When you are finished attaching the reinforcement plate to the motor, there should only be a few thousands of an inch play up and down with the sunroof drive gear. It should sit up quite a bit higher than when you removed the motor.

Thanks,
Dave

jazamm42

I've taken everything out repaired the housing and my tracks are out of sync with the driver side a good inch behind the passenger side panel mechanism and I have no idea how to get them to adjust. I've tried moving both to full open and full closed and also tried to force the full closure with manual drive to no avail. Does anyone know what to do to even up the panel mechanism? Thanks for any input.

drb930

You should be able to grab the open sunroof (with the motor out) and wrestle it around a bit to even up the sides.

Thanks,
Dave

jazamm42

Your direction is much appreciated. I threw a couple curves at my fix though, I made a shim for the inside of the housing between the housing top and the plastic gear and since I had the glass out I adjusted the runners in their tracks with a rubber mallet and blunt punch very easy to tap into position. But couldn't have done it without you letting me know the little stuff I was afraid of damaging., Thanks again, Jeff

herbie

Hi, i know this thread is kinda old, but i'd rather use this than create a new one. We just got my mom a used 2004 c230. the sunroof visor (the black cloth) would not close. Since she doesn't intend to open the sunroof, closing the visor would be really helpful since it gets super sunny here in CA. Is there a way to close it? whenever i try closing it, the motor just grinds. i read something like pushing the motor. where would i push it? do i need to remove any parts? any help would be greatly appreciated.

thanks,
Herbie