SQLGuy

Hi folks,

I did search, but found one concise thread about removal without a sunroof, and one somewhat confusing and contradictory thread that spun off more towards sunroof repair than headliner removal (this one: https://rennlist.com/forums/928-foru...-question.html).

I have a warped headliner in my '93 GTS. I also have a pretty decent water leak from somewhere at the top of the hatch. Not sure yet where it's coming from, but I hope to be able to better diagnose it once all the damaged parts are out. The hatch seal looks pretty good actually, but I also bought a new one.

Anyway, I have the visors off, and the perimeter screws out, and the sunroof open. Can someone tell me what I should and should not remove in the sunroof area to get the old headliner out? I have a used, non-warped, headliner underlayment that another Rennlister was kind enough to donate (left over from his sunroof delete operation). Once I have the old one out and the leak(s) fixed, I plan to get the new one covered and installed.

Thanks for the help,
Paul

Ducman82

on my 81 you take the front strip, and rails off the sunroof to release the liner.

Lizard928

You need to remove the sunroof to remove the headliner in a sunroof car.

It is not an easy project, take your time and be careful not to rip the vinyl that is in the sunroof space.

SQLGuy

OK. So, two responses, and already a disagreement.

Colin: Ducman was specific that his experience with not having to remove the sunroof itself was for an '81. Can you clarify which year(s) you've found that the sunroof itself does need to be removed?

Thanks,
Paul

Ducman82

i never had to remove the sun roof. it goes back far enough that i was able to get all the screws out.

SQLGuy

In mine, it does not seem to go back far enough. I think I will need to remove the sunroof.... didn't really want to do that. :-(

Ducman82

its been awhile for me, but i might have used my little angled ratchet screwdriver thing. but taking the sun roof out is that not that really. just the 3 screws for the liner, then a few more for the shuttles. bingo.

SQLGuy

OK. Sunroof's out. Headliner's out. And I think I see where the water's coming in...

I found a hint here: http://jenniskens.livedsl.nl/Technic...5/MyTip593.htm

"It turns out there are 2 square holes in the roof (under the
headliner) approximately 4.5 inches forward of the hatch opening, one on either side of the roof centerline. It seems that they are somehow related to the sunroof rail structure mounting. I had a nice little flood coming through the right side hole. I highly suggest that if anyone is still suffering from water leaks after repeatedly cleaning the drain holes, take the sun roof motor cover off, loosen the headliner in the rear (2 screws) and have someone pour water on the rear edge of the sunroof while you slightly bend the headliner down (gently...) and watch these two holes for leaks."

Those holes, pretty close to the sides of the ceiling, do look like the source of the water that soaked my headliner. The question is, why is water getting above them? The drain tubes are connected, though I haven't verified yet that they're not clogged. Is this just a symptom of a bad sunroof seal? (The seal does look pretty old and shrunken, but I always thought that the sunroof was designed so that water that gets through the seal would still drain down the tubes, not into the car.)

Thanks,
Paul

Ducman82

pictures!

SQLGuy

OK.

Taking the pictures also led to the solution. There's a plastic ledge on the trailing edge of the sunroof. It deflects water that leaks through the back part of the seal into the drain gutters... or it's supposed to. Mine is cracked where the mounting bolts secure it to the sunroof itself. This is letting water down into the area behind the sunroof, and from there, into the car.

Mrmerlin

if you have a dark colored car the rear sunroof drip pan will usually crack from the excessive heat if you replace the tray this should cure the leaks.
make sure to chase the drain holes dont use compressed air it can blow off the hoses and then your really gonna have fun putting them back on.
Use weed wacker line

SQLGuy

OK, but, where would the lines get blown off from that I couldn't easily put them back on? I do have the headliner out, so I have full access to where they connect to the drain holes.

SQLGuy

Hi folks,

I got the replacement, non-warped, headliner, but I'm not sure if it helps me any. It has good foam on it, but no vinyl and no frame for the opening. I might be able to transfer the vinyl from my old headliner, but the old frame is broken in a few places, and more-or-less disintegrating.

Is it possible to get a replacement plastic frame for the opening? I checked McMaster-Carr, but they didn't have any L-channel plastic in the right size... and even if it were thermo-formable, bending such plastic into the correct shape seems unlikely to work...