Martin H,
Just when things are looking up it would now appear that I generate problems!
Grrrr will like this after his recent ordeal!
My P38 has had a big hole in the roof for well over two weeks now - that is the reason why we are all getting so much rain currently.
I only stripped down the Sunroof as it was beginning to bind, (although it worked fine when I got the vehicle), and the timing was opportune as I had removed, (and recovered), the headlining and I needed to strip the sunroof in order to get the blind out, (for recovering).
After two strip-downs, (and subsequent rebuilds - each time being extremely cautious with my freshly covered blind), the motor would still stall, occasionally, so I was determined to sort it before re-attaching the headlining.
I therefore decided upon a third full strip and rebuild, (possible hint of a 'I keep cutting this bit of string but it is still too short' moment), this time taking lots of photo's so that I could do a full write up, (there are lots of posts related to sunroof's but no full procedure - apologies if there is and I didn't find it!
After the third rebuild, (taking photo's all the way), and even having time to take a break, (installing a new front master cylinder to my Suzuki and then bleed the brakes), I proudly installed the assembly back into the beast, (having checked all of the functions/movement beforehand), only to experience the same motor juddering when I attempted to fully open the glass panel.
There was one exception, on this occasion, the glass panel became completely stuck and it was impossible to move the glass in any direction, (via the motor control or via the mechanical override), so I had no option but to remove the assembly yet again, (for the fourth time - but who's counting)!!
Things didn't get any better once I had the assembly back on the bench as I couldn't get to any of the rail mounting screws in order to release the mechanism and no matter how much pushing and shoving I gave the panel it would not budge.
I presumed, (incorrectly), that a foreign object had fallen into the mechanism and jammed it but this was not the case.
I had absolutely no choice but to try and lever/force the glass panel out of the way, (the panel occludes the various mounting screws), and, (as the panel was partially retracted), the panel mounting Torx bolts, themselves, were also inaccessible!
The inevitable then occurred - there was a loud SNAP and one of the glass panel retaining lugs sheared off its cast metal mounting bracket.
I was now able to access the rail mounting screws and I soon had the rails separated from the main metal chassis and it was now evident that the right hand slides were completely seized in the right hand rail!!!!
It took a rubber headed mallet to persuade the slider to come out of the rail and I have spent the odd hour, (every day this week), lightly sanding, (and 'wire wooling'), the rails in order to reduce the friction that has suddenly appeared.
I ordered a tube of 'JB Weld' on Monday, (and it arrived yesterday), and I have managed to repair the broken lug, (only time will tell if the joint will support the glass panel), but the joint looks very good, (strong and solid), so my fingers are crossed - I also repaired one of the lantern frames on one of our lampposts whilst I was at it!
So I am now trying to reduce the friction, (on both rails), to the absolute minimum before I re-install the assembly once again.
There was no foreign bodies caught in the rails/mechanism the rails are straight and true, (no warping or twisting),so I am at a complete loss as to what has occurred and I am even considering any 'esoterical' factors, (temperature differentials causing different expansion of materials, oil/grease absorption into the nylon/plastic sliders, etc), perhaps Wammers may have seen, (or heard of), this particular issue, (although he may state that it is simply down to my ham-fisted handling of the assembly!
I am hoping that my next post may be a little more positive!!
