Sunroof woes

[Davecars]

hi all

been away for a while and the RS2 is still in the garage, decided to wheel it out only to find the sunroof seems to be seized, I removed the headlining and sunroof cassette, the motor was jammed but I had a spare, motor replaced but still will not move from the shut posistion, anyone have this problem before (metal sunroof by the way), or is it find a second hand unit and fit that ? (does the S2 avant sunroof fit) All help greatly appreciated.

[Tractor Dave]

Have you tried winding it manually with the tool that should be in the housing? Mine was very stiff and bent the tool!
I then removed the tracking and re greased it but you have to wind it all the way back to get to the tracking.
S2 Avant and RS2 sunroof is identical as far as I know.

[Davecars]

Hi Dave

Tried that (with motor out) but was worried I would break something inside the gearbox, Is there anyother way to get into the mechanism ?

[Tractor Dave]

If its not been open for a long time, the seal has probably swollen slightly and stuck to the roof. Try spraying some warm washing up liquid solution all around and work it into the seal with a car wash brush. If you can find something thin to fit the gap that wont scratch the paint you could slowly work that in to make sure its not stuck. Something like a plastic cake slice?
Then try again from the inside with the tool. Mine was very stiff.

[Davecars]

Hi Dave

I have the complete cassette out of the car so not the seal, I thought once it was out I would have access to allow me to move it, but I can't see any way other than forcing it with the supplied key, still worried I will do damage.

[Tractor Dave]

Well, if it's out of the car, saturate everything in wd40 and leave it to soak overnight whilst you recover with a beer

[Davecars]

That's the best suggestion of the night

[Bowie69]

Take the motor off, then you can get to the cables and manually push the roof backwards and remove the cables.

[SteveH]

If the cables have rusted in the channels it might just be easier to find another usable cassette. BTDT. Spent hours cleaning/greasing and the mechanism was still very slow to operate. Bought a replacement and wished I hadn't wasted loads of time and materials.

[Davecars]

Hi all

got the dam roof to move, removed the roof to find the cables were very dry and covered in like string (see photo) also I’m a bit confused there is a plastic part that slides, at the very back of the roof and it doesn’t seem to be connected, any ideas.

[Davecars]

Sorry, forgot to post the photo of the string

[newsh]

I think the string is there to hold the grease.

The plastic piece is the drip tray, it sits beneath the edge of the moving panel when it’s closed and channels water to the sides from where it can reach the drains. It’s clipped to the moving part of the roof with the two pieces seen in your pic.

[newsh]

[Davecars]

Thanks for the explanation, I've removed the loose string and left the rest in place, re the drip tray, I have tried to clip in on but every time I move the roof it pops off, I could use a cable tie to secure it and at least it would do the job it's supposed to, now cleaned and moving I need a roof seal and I am pretty sure the motor is shot, any ideas where to look for these parts, many thanks for all the help so far.

[Tractor Dave]

There are a few on ebay or search Audi 80 avant breaking on ebay.