TheSamba.com :: View topic

Mon Jun 21, 2004 9:04 pm

Hi i recently bought a 66 bug and the sun roof needs new cables and a seal could any one give me any advice on how to get the old ones out ?

Tue Jun 22, 2004 3:44 pm

Try this guy he may be able to help.
I also noticed a place in one of my rags.I want to say Hot VW's.They sell parts for sunroofs.Take your time.Get good replacement parts.Steve

Wed Jun 23, 2004 12:19 am

thanks but all i found on that web sit is vert parts i have a local vw parts store that can get the parts i just need some idea on how to take it apart and put new cables on

Fri Jan 21, 2005 4:51 am

Hi ihave exactly the same car and exactly the same problem. I have in my notes so far-

Quote-

"The gear is almost never worn, neither are the cables. What does get worn, or bent is the metal plate that goes on top of the gear where the cables cross. This should lock the cables and the gear. Bending untill the cables are tight to the gear takes a while but was for me the way to go. Finally you have to adjust the lift of the roof. At the end of the cable where it hooks into the roof there is a nut and screw on both sides. Close the window and push the roof up, then adjust the srews and nut till it remains closed, but the cables can move another quarter inch. It is important that the roof is positioned straight and that both cables are lifting the roof at the same time. If one side starts lifting earlier then the other, that cables moves over the teeth and the window won't close. "

Which is good news for me as i had a set of new cables and seals stored in a rubbish bag on my patio, but the garbage man kindly mistook the bag as rubbish and disposed of it!!!!!!! D'oh!

Ive not tried any of this as yet due to the vast range of weather we get here in england, but i plan to very soon......what this guy had written about the cables wearing makes a lot of sense to me (being an aerospace engineer by trade!)

If i learn any more ill let you know and hope you'll do likewise. Hope this helps!!

Take it easy!

Fri Jan 21, 2005 7:41 am

The Bently manual clearly shows the adjustment procedure.

Fri Jan 21, 2005 8:51 am

That is good news! I'm awaiting a copy as we speak and i'm really glad i ordered one now! - Thanks.

Fri Jan 21, 2005 4:15 pm

BFY obsolete has repo everything for the sunroof with the exception of the aluminum rails (do not lose these or you are f#*$%ed) for fairly decent prices. Removal is not tough, pop the headliner plate off, which covers the metal underside of the roof. Open her up and start taking it apart, noting order of removal or anything notable that will help reinstall.

Matthew Henricks supplied the following advice for me on sunroof install:

First off, on the 67 are there two round height
adjustment knobs at the front corners where the roof
track fingers are? They would be about 2" diameter
and knurled.

Best i can remember is that you assemble the entire
mechanism and put it in as a unit. That is you need
to put the cables into the rear mounts on the roof and
then slide the cables into the rails. There are two
cable slots per rail and up at the front near the gear
the cables switch grooves so make sure you slide them
into the right slots. Seams to me that one was on top
and the other on the bottom the gear plastics made
them go up/down to the alternate slot as they passed
by. You will have to look and check that out.

Leave the cables free hanging once they are installed
in the tube. Bring the whole unit (roof & rails) to
your car. Protect your car so things do not get
scratched. I think you want the roof panel towards
the front of the car and you slide the rails into the
roof while supporting the front of the assemble. Once
it gets in there the roof will drop into the hole and
the rails will lay in there mount areas. The trick
here is to get the rear plastic rail guides (That are
pressed into the rear of the rails) to slide into
their holes inside the roof without breaking them. If
you do not get these in there the roof will not work
very well. I really do not have any tricks there but
to keep trying. I ended up breaking one of mine and
having to find a replacement at a junk yard.

Once the rear of the rail is in then you can screw the
rails in. Manually slide the roof back and forth to
make sure it moves smoothly. You have to fiddle with
it until it is smooth. If it jams up or is not smooth
you will break your handle, strip your gear or worse
break your cables. the rest is straight forward.
Route your cables into the plastic housings and gear
system and test it again. Make sure you have the roof
square and are pulling evenly on the cables. You will
be able to tell if you are not because the roof will
twist when you change direction (Open/close) Adjust
the cables on the gear as needed.

As for the headliner. You can put the system in if
the headliner is in place but you may have to be a bit
more careful. The headliner piece for the sunroof
should be installed after the roof is on. It just
snaps in place.

A few other tidbits.

Grease up your cables before you put it together.

The rear plastic retainers may be available now as
repros.

Take your time. Nothing worse then scratching things
up because you are in a hurry

Put some grease on the tabs in the roof where the rear
of the sunroof is raised up. These are two little
ramp looking things. Over time the paint will wear
off and then the roof will be harder to close all the
way.

If your roof has the 2 small adjusters (See my first
question way up top) let me know and will expand on
them.

Never force your sunroof closed. If it is jammed, tak
it apart. Cables are like $150 EACH!!!! Plastic
handles are available but they are not like the
originals. Gears are not available to my knowledge.
I made it a habbit of taking these parts from
junkyards when i used to have time for that so i would
have spares thru life.

Make sure your rear drain tubes are in the roof
securely. You will have to remove the headliner to
check that. also make sure they are secured in the
rear quarter panels above the drain outlet in the
panel just above the running board.

The front drain tubes run into the front quarter
panels. If you have/had rust there that is why. It
sort of sucks. I rerouted my front tubes out the
front fenders well from inside the hood to stop the
rust. works great.

The tubes get blocked up real easy. Compressed air
from the bottom works great to clean them out.

Hope this helps, haven't had time to put mine in, but will soon!
(above quoted from Matt Henricks)