Sunroof still stuck closed

There are two generally reasons why a sunroof may stick:

1. The drive is stuck
2. The runner/slide mechanism is stuck

On the first, if you remove the plastic panel at the back of the roof headliner you can unbolt the motor and then the gearbox. The latter engages in the two drive cables (one for each side) with a gear. Removing it should allow the drive cables to move in their tubes without the motor or gearbox hanging them up - if that is the issue.

The second is more likely since typically screws loosen and or the plastic parts break, resulting in a jamb as pieces get out of place. You have to remove the sunroof headliner to get to these, and as noted in the referenced methods, you have to get to three screws at the front edge. To be clear, as I missed this initially, the screws are horizontal and deep in the gap between the sunroof top panel and the sunroof headliner where the wind breaker goes as the sunroof closes. Knowing that, if your sunroof is even open a bit, you can get a flexible shaft screwdriver in there to loosen the screws - they don`t have to be undone, but it does help. Once the sunroof headliner is removed, which is not a fun task, then it is easy to unbolt the sunroof and components from inside the car.

Martin,

This second point is a good and important one...

On EURO85 I was noticing that the sunroof did not line up very well... It was WAY lower on the passenger side rear and was not properly flush even on the drivers side, so this time when I had it in the shop I asked them to take a look at it. Didn't even take them an hour to fix, but it was missing or lose screws all over the place and that is why it was funky. Now it fits PERFECTLY and looks AWESOME as the lines of the roof are now smooth as they should be! It also takes the risk out of damaging something because now it is all tight, straight and lubed up! YEA!

BTW, I pick the car up tomorrow and all that will be left are some interior and exterior cosmetic things and that car will be SO SWEET!!!! Exhaust in on and sounds MEAN! Car seems (according to the guy who owns the shop and has 2 928's of his own) running well too! Can't wait for better weather to start racking up the miles on that bad boy!!!

I've discovered a couple of other failure modes from reading and personal experience:

1. The ends of the drive cable can come off - but this just means the drive will not be able to move the sunroof, not that it will actually jamb
2. The rear drip tray can break and cause a jamb. Mine was broken (see my car profile posting) but fortunately the broken piece was pushed to the back of the opening and only impaired the extent to which the roof could open, but it is easy to imagine that it could have lodged under the sunroof

Thanks Martin. In the spring I will try again to get the roof to move more than 1/2 inch so I can access the screws. With the motor and gear out I can only get about a 1/2 inch movement. I will also try some wd40 on the sides to see if it will penetrate and help lube.

CARLO;3631 wrote: Thanks Martin. In the spring I will try again to get the roof to move more than 1/2 inch so I can access the screws. With the motor and gear out I can only get about a 1/2 inch movement. I will also try some wd40 on the sides to see if it will penetrate and help lube.

With the gearbox out, you can also access the rear end of the two drive cables - I'd suggest some WD40 or PB Blaster there too.

If the cause is dried or gummed/dirty lubrication I expect that the sunroof will move slowly but not necessarily stop in exactly the same place, especially if you are helping it.

On the other hand, if there is a loose piece jamming it, then a sudden stop is more likely. I found in mine that a piece of the rear drip tray had broken off, but fortunately it had been pushed to the end of the sunroof recess. However, it could easily have jammed up the roof just as it started to open.

Good luck.

Sorry if I repeat someone else's answer to 928 stuck closed sunroof.
Here is what happened to me with my recently purchased 1984 Black 928S.
After fighting but trying not to damage anything, I still did not find why my sunroof would drop in back but not retract. The motor and gearbox work but with both out the sunroof panel would not move.
"My" mechanic (works extensively on Porsche) tried for nearly an hour, but finally found that the sunroof panel leather had stuck to the polished bar that crosses the rear of the opening (visible when the sunroof is open. He carefully used a somewhat hand made thin tool that lacked sharp edges or corners, that he worked at the back of the sunroof (inside) to "unstick" the leather from this polished bar.
Upon unsticking the leather the sunroof worked/works flawlessly. He recommends cleaning this bar regularly and a couple of times a year spraying it with silicon spray.
I can provide a picture of this polished bar if you need.
Hope this helps.
Porsche356
'56 356A, '99 996 coupe, '84 black 928S