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Thu Jun 25, 2009 11:54 am

My sun roof is difficult to open, but does open. What can I do to make it open more easily? I searched the Type 3 forum and I couldn't find any posts about it. Is the sun roof the same for the Beetles? Should I look in that forum for help? I don't want to go taking the roof apart and not be able to put it back together...

Thanks!

Thu Jun 25, 2009 12:04 pm

Woreign wrote: My sun roof is difficult to open, but does open. What can I do to make it open more easily? I searched the Type 3 forum and I couldn't find any posts about it. Is the sun roof the same for the Beetles? Should I look in that forum for help? I don't want to go taking the roof apart and not be able to put it back together...

Thanks!

Woreign, I got to pick up my Sister, so do not have time for finding the write up/writing a long post, but when I get back, will do.

Thu Jun 25, 2009 12:43 pm

Its not to difficult to take apart. If you decide to, then check the cables for wear and grease them. Make sure the guides/rails are free of obstruction.

Thu Jun 25, 2009 12:46 pm

And that the drain tubes are open and functioning.
I do have the sunroof manual in PDF format. This is for the Rabbit, but it is the same roof.

Thu Jun 25, 2009 1:34 pm

I have a questin along the same lines.... The instructions in the Bentley Manual say that the roof has to be open 2" before you can pop out the inner panel to access the cables and adjustments. Mine is frozen solid and won't move to get it open that far. Is there another way, besides dynamite?

Thu Jun 25, 2009 2:22 pm

57baja wrote: I have a questin along the same lines.... The instructions in the Bentley Manual say that the roof has to be open 2" before you can pop out the inner panel to access the cables and adjustments. Mine is frozen solid and won't move to get it open that far. Is there another way, besides dynamite?
Remove the crank gear. It may be wound to the wrong end. It has to be wound counterclockwise (as your looking up at it) all the way with the roof shut. I made this mistake when I fisrt installed mine. It would only open half way. I thought it was stuck. Turned out I had the crank gear wound half way through.... Hope that makes sense.
It may not be your issue, but you never know. Sometimes its a simple fix.

Thu Jun 25, 2009 2:36 pm

57, I never had the problem, but if it was me, I would remove the handle and plate, remove the gear, and gently see if I could move the roof. Then, soon as you can reach the front edge of the headliner panel, unclip it, and slide it back.

Once everyone has there headliner panels removed, you can remove the steel panel. This will allow you access without having to further move the panel. Look on the inside, and on each side, there will be a bracket with two Philip head screws, remove them. The panel should come out. Now, get out you camera, and photograph what you have, and document what you are doing. Will help to put it all back. I apparently did not take any photographs, as I do not find them here. There are, however several right ups covering it.

Consult the Bentley now for how to remove all the plastic bits. I would recommend hitting all the screws with a penetrate. Once all the plastic parts are removed, the gear drive is removed, you can pull out the cables, I.I.R.C.. The cables will be a real mess, covered with grease and who knows what. Clean them with solvent, be a good idea also to clean the guide tubes.

Now, what if you need replacement parts? Type 1 cables will work, but are too short. The roof will not fully open when using them. The plastic parts and hardware are all Type 1 parts, except the corner pieces, I.I.R.C.. All the rest is type 3 specific. All parts can be had at I.S.P. West, but be prepared to pay a hefty sum. It will be an investment, as they should last a long time if taken care of.

Once everything is out, clean all four drain tubes. I used a bike brake cable. Also, a good time to address the rust, and make things neat. Also, you can install the felts, if so needed. They do not stop water, but wind noise.

Now that everyone is ready to put things back, put in the cables, guides, everything but the top center plate. Once to this point, pack the center guide and gear with grease. Get happy with the grease. When you put on the cover, some grease should ooze out. Clean up, and put the metal panel on. Hopefully, the cables are matched to each other. Been a while, but I think I put both to the very front of the side tracks. Once the panel is in, adjust per the Bentley. Check to be sure it moves nice and smooth, and there are no issues. Once satisfied, put in the headliner panel, and smile knowing you have a special way of injoying the breeze and the sun. 8)

Thu Jun 25, 2009 3:03 pm

Thanks to everyone for your replies! With all the knowledge you have shared, I was able to disassemble, clean, and reassemble the sun roof with now problems. I now have a smooth sliding roof!

Fri Jun 26, 2009 9:40 pm

Adriel Rowley wrote: 57, I never had the problem, but if it was me, I would remove the handle and plate, remove the gear, and gently see if I could move the roof. Then, soon as you can reach the front edge of the headliner panel, unclip it, and slide it back.

Once everyone has there headliner panels removed, you can remove the steel panel. This will allow you access without having to further move the panel. Look on the inside, and on each side, there will be a bracket with two Philip head screws, remove them. The panel should come out. Now, get out you camera, and photograph what you have, and document what you are doing. Will help to put it all back. I apparently did not take any photographs, as I do not find them here. There are, however several right ups covering it.

Consult the Bentley now for how to remove all the plastic bits. I would recommend hitting all the screws with a penetrate. Once all the plastic parts are removed, the gear drive is removed, you can pull out the cables, I.I.R.C.. The cables will be a real mess, covered with grease and who knows what. Clean them with solvent, be a good idea also to clean the guide tubes.

Now, what if you need replacement parts? Type 1 cables will work, but are too short. The roof will not fully open when using them. The plastic parts and hardware are all Type 1 parts, except the corner pieces, I.I.R.C.. All the rest is type 3 specific. All parts can be had at I.S.P. West, but be prepared to pay a hefty sum. It will be an investment, as they should last a long time if taken care of.

Once everything is out, clean all four drain tubes. I used a bike brake cable. Also, a good time to address the rust, and make things neat. Also, you can install the felts, if so needed. They do not stop water, but wind noise.

Now that everyone is ready to put things back, put in the cables, guides, everything but the top center plate. Once to this point, pack the center guide and gear with grease. Get happy with the grease. When you put on the cover, some grease should ooze out. Clean up, and put the metal panel on. Hopefully, the cables are matched to each other. Been a while, but I think I put both to the very front of the side tracks. Once the panel is in, adjust per the Bentley. Check to be sure it moves nice and smooth, and there are no issues. Once satisfied, put in the headliner panel, and smile knowing you have a special way of injoying the breeze and the sun. 8)

Excellent post Adriel. Thank you. I took the crank handle and gear off and was able to pound and pull and cheat the sunroof just a hair back to gain access to the front inner panel. I popped that loose and slid it back. Then I shot some Liquid wrench in the groove where the cable is. I got it to slide all the way open that way. Then I cleaned the tracks a bit and lubed it some more. The PO painted the damned aluminum guides, and all the paint is blistering, so I sanded that down a bit. I got the room to glide easily for the last 7/8 of the way, but it binds when it is closing that last little bit. I think the cables are stripped for that last little bit. I'll do a better job of taking it apart and cleaning/lubing it better later. For now.... since it's summer, I'm going to leave it open and drive around for a bit with it. I'm taking it out tomorrow on a SoCal Bajas run.

Sat Apr 11, 2020 1:17 pm

how do you get the cables out.. ive pulled the side rails and had them sitting for a few days to lubricate as they were really rusty and the car was outside in a field for who knows how long.. any idea how to remove them? thanks scott

Sat Apr 11, 2020 2:22 pm

dustysbug wrote: how do you get the cables out.. ive pulled the side rails and had them sitting for a few days to lubricate as they were really rusty and the car was outside in a field for who knows how long.. any idea how to remove them? thanks scott

I believe they just slide out of the guides. Yours might be packed full of dirt, not allowing them to come out.

Sat Apr 11, 2020 8:33 pm

thanks bob,

ill try again.. i don't see any dirt in them but they are really rusty looking as the car sat with the sunroof open in a field for many many years..

ill try and pull them out i just didn't want to force them out.

Sun Apr 12, 2020 9:56 am

dustysbug wrote: thanks bob,

ill try again.. i don't see any dirt in them but they are really rusty looking as the car sat with the sunroof open in a field for many many years..

ill try and pull them out i just didn't want to force them out.

Keep in mind the side guides are aluminum, with the front corners made out of stainless steel.