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  #1  
Old 03-28-2024, 12:05 PM
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Water in front of sunroof cassette, not going in drain hose?

Hey guys. So I fixed my pano roof. Well mostly. It works great. However the other day we had some heavy rain and there was a drip from the front left corner. Damnit

I was able to push up on the cassette in that corner and it moved a bit. So I cranked those bolts a little tighter in that corner and it slowed down. I used the torque wrench originally to whatever the factory said 10 newton meters I think, but since I reused the bolts maybe that wasn't good enough. Tightening those four bolts just a little bit more helped slow it down to a very slow drip, but it's still dripping.

If we get a really heavy rain there's a small bit of water that seems to accumulate in the one front section of the cassette that doesn't go down the drain hose. This morning there was no more water on the driver's seat or bottom of the cassette rail, but when I made a right turn I had five or six drops of water roll out and hit me on the arm.

Thankfully I haven't put the headliner up yet. Which is now covered in a nice new black fabric. So I have to pull the whole thing down again I guess and look at it, but I'm wondering if I can just lower the front half a bit and fix it up.

Wondering why this would leak like this if anybody knows. I replaced the outer seal and did a pretty decent job on it that all looks good. Maybe I didn't and need to do that again. I don't know why water is getting into it in the first place, but it's not going down the drain it's just stuck in the cassette for some reason. The drain hose is unclogged. Disconnecting it up there, it's all completely dry. There's water right next to it but it's not going in. It's like there's a uphill downhill problem inside the cassette maybe .. i don't know.
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  #2  
Old 03-28-2024, 12:30 PM
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Id use some silicone as backup to the job ...but I'd use air nozzel to blow out first.

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Old 03-28-2024, 02:47 PM
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I rebuilt my sunroof cassette but wasn't able to replace the glass seal as it was integrated into the glass assembly. still had some drops coming from the overhead console sunroof switch, so when the truck sits with the rear bags deflated, any accumulated water will drip to the back drains.
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Old 03-28-2024, 02:57 PM
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If you use an air hose keep the psi low and slow or it can blow it off the connector!!

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Old 04-05-2024, 12:28 PM
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Well we got a bunch more rain. Torrential rain for 2 days. And there was a bunch of water on the driver's seat this morning. The damn things leaking. There was a couple drops on the same side rear seat as well.

Did I just do a bad job on the seal and need to do it again? Not really sure what to do here I feel like this is going to be an ongoing struggle. The seal looks good. Maybe just tighten it more? Loosen the glass move the glass around maybe? I can silicone the one side of it but not the side where the glass contacts it.

I've been trying to flash the computer module with the latest software but have not been able to get that to work yet. The parts bag for the seal said it required coding, I read somewhere that they redesigned the seal and there's a software update to make the glass close correctly. I still haven't been able to do that. Maybe that will save me. I have ISTA+ working with this car, but the software update tab is greyed out and I don't think it should be. I'm going to continue to look at that and maybe one of the older ways of coding it with NCS expert or whatever it is.




I guess I'm going to cut the grass
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Old 04-05-2024, 03:50 PM
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Drain hose kinked?
Info in this forum..
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Old 04-05-2024, 06:57 PM
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I'm with others and lean towards the drains. The sunroof cassette seals themselves aren't designed to be water proof. The seals are there to keep out most water and the diverter across the middle and the drains are supposed to do the rest.

That said, the main seal (the one attached to the body) that runs the entire perimeter of the pano roof can shrink, it is 19 years old, or was designed small. We had a small leak due to it. When I replaced ours with a new one it was decidedly thicker than the one we took off (removing the adhesive sucks, swear I'm still missing some fingerprints on my thumb).

Open the shades and have someone use a hose on targeted parts of the roof. Easiest way to see where your issue lies. But like I said, some water is designed to come into the cassette.
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Old 04-09-2024, 12:41 PM
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The drains are good. The passenger side originally was very clogged, I had to use the trimmer wire to get it moving. But I blew all four out with a little air and the garden hose and they're good.

It's like the water isn't making it to the drain. Like there's a low spot in the cassette and it's pooling in a particular area in the cassette. And then it's not sealed internally and it's spilling out. I will probably drop the whole thing down again this weekend look at it. Maybe I have to do something to level it out. And I will probably get the silicone gun and have at it.

The salvage yard had one with a pano roof I might have to go get that cassette. If anybody wants it let me know I kind of want to go get it anyway.
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Old 04-09-2024, 10:24 PM
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I've got one from an e83...used silicone to attach the rubber connection hoses.
Noticed the drains are small.
Seems to me the drain size is not adequate from the start of course it does work...I suspect best not allow in the least bit of debris or your having experienced problems.
I'm taking the cassette frame back to the salvage yard once I remove the front and rear motors.
Attachment 84091Attachment 84092

Last edited by getty150; 04-10-2024 at 12:25 PM.
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