sunroof 4000CS

Jim Dupree jdupree914 at
Tue Aug 23 15:58:19 EDT 2005

Slow down a bit!
First you need to get the sunroof headliner out of the
way so you can see what is causing the roof to bind.
Tilt the roof up and then get out of the car and look
in under the roof panel . You will see the center
portion of the headliner tilted up. If you reach in
you can push down on it and see that it is held up by
1 or 2 springs. Make a hook out of a coat hanger and
reach in and pull the spring(s) just enough to get the
to unhook from the headliner. Once the center of the
headliner will lay flat on its own then you get back
in the car. 
Here there are 2 options
Early cars:
(I don't know when the change was made)
Run the roof closed again and then run it back what
little it will go. reach up and pull down on the front
edge of the sunroof headliner panel. there are 5 snap
clips holding the front edge. When you get all 5 clips
loose you can slide the sunroof headliner back inside
the roof.
Late cars:
Leave the roof tilted up and pull back on the sunroof
headliner. It has clips that hold it forward on the
front sunroof hinge assemble. I usually would give it
a smack with a fist on the back edge of the center
opening in the headliner panel. It should pop loose
and you can slide it back out of the way.
I don't know how to tell you which set up you have but
I would try the later method first.
You now have access to all the sunroof guides and tilt
mechanism. Run the roof forward and tilt it up. then
run it back and try to run it back into the main roof.
watch the guides and see where it binds.
Common failures:
The drive gear for the cables wears and then slips.
The housing around the drive gear spreads under load
and allows cables to slip.
Cables stretch and wear and slip out of time.
The guides mounted to the roof panel break.
The tracks get gummed up with old grease and dirt.
Spray on white grease has ruined several sets of Audi
sunroof cables that I have seen. It hardens with heat
cycles and becomes clunks of debris.

Good Luck

--- Tony Hoffman <tfh400036 at> wrote:

> The best thing to do is pull the sunroof out. Oh,
> wait, it has to slide open first!! OOOOPS!!
> Seriously, 
> Start by opening the sunroof as much as it will go
> toward the rear. Then, pull the sunroof cover. The
> one with the switch, that is. Then, pull the screws
> that hold the motor assy in place. There are two,
> they have slotted openings they go through. The two
> shorter ones just hold the motor assy together. Now,
> you can see if you can slide the sunroof open any
> farther by hand. Sometimes it is necessary to push
> down on the rear of the sunroof where it goes into
> the back of the roof. If you can get it to slide
> open, you are on the downhill side. If not,
> something inside the sunroof mechanism is broken or
> lodged, and I'm stuck there.
> If you got the sunroof open, pull the countersunk
> screws on the top of it. There are two on each side
> of the wind deflecotor. Pull the other tow for the
> actuating rods first, then those four. Then pull the
> rest, and pull the covers off the cables. The cables
> may fly out at this point. Now you should be able to
> pull the whole sunroof assy out, clean and
> lubricate, and put back together. While it is
> appart, look closely for anything broken. Quite
> common are the pieces on each side that guide the
> lid up and down. They have a groove and a slot in
> them. 
> Anyone remember anything I might have forgotten?
> It's been a while since Ive had a 4000 sunroof out.
> Oh, on the 90, you should be able to pull the whole
> assembly out of the car in one piece. In other
> words, don't pull the short screws out of the side
> rails, They hold the top and bottom together.
> Tony Hoffman  
> Evan Parker <evan at> wrote:
> Mine does this exactly as well in my 90q. PB blaster
> didn't help it at
> all :( I have no idea what to do with it.
> Subject: sunroof 4000CS
> Greetings all,
> Working on the newly acquired 86 4000CS. While
> waiting for parts
> ordered thought I'd work on the electric sunroof. It
> will tilt up
> normally but will not slide back. Starts to go back
> about 1/2 inch then
> stops. Hand over-riding same thing. Gets stuck tight
> after trying to
> hand open. I have the Bentley put it is very sparing
> in info for some
> topics. Any tricks?
> EricH
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