Section 35 (Body - Interior & Exterior - 500 - Electric): Sunroof: Sunroof: Removal: Removal

WARNING: This page is about a different variant/trim than selected.

CAUTION:

Take extreme care not to bend the sunroof frame during the removal process. If the sunroof frame is bent, it will be necessary to replace the sunroof frame with a new service component.

CAUTION:

Due to the extensive usage of urethane as the bonding material, only a skilled technician with proficient glass removal experience should attempt this procedure.

CAUTION:

Use appropriate cautionary measures to avoid damaging the painted surfaces of the vehicle.

Fig 1: Headliner

Courtesy of CHRYSLER GROUP, LLC

Remove the headliner (1). Refer to HEADLINER, REMOVAL .

Fig 2: Overhead Console Mounting Bracket
Courtesy of CHRYSLER GROUP, LLC
Drill out the three rivets securing the overhead console mounting bracket (1) to the roof header.
Remove the overhead console mounting bracket (1) from the roof header.

Fig 3: Windshield
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Remove the windshield (1). Refer to WINDSHIELD, REMOVAL .

Fig 4: Glass Panel & Two Torx Screws
Courtesy of CHRYSLER GROUP, LLC
Remove the sunroof glass (2). Refer to GLASS, SUNROOF, REMOVAL .

Fig 5: Glass Guides & Guide Belts
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not allow the sunroof guide belts to route under the sunroof guides. Damage to the sunroof guide belts may occur.
Use the sunroof switch to move the sunroof glass guides (1) toward the full closed position, stopping periodically to inspect the sunroof glass guide belts (2) positioning.
The sunroof glass guide belts (2) will curl under the sunroof glass guides (1), do not allow the belts to be pinched. Stop and redirect the sunroof glass guide belts (2) to remain out from under the sunroof glass guides (1).
Once the glass guides have reached the full closed position, disconnect and isolate the negative battery cable
.

Fig 6: Bottom of sunroof shown, displaying urethane front bead (1) and full perimeter urethane bead (2) locations.
Courtesy of CHRYSLER GROUP, LLC
Remove the sunroof switch and disconnect the sunroof wiring harness connector, located on the A-pillar.

Fig 7: Sunroof Spacers & Masking Tape
Courtesy of CHRYSLER GROUP, LLC
Apply 2-3 layers of masking tape (2) to the perimeter of the sunroof to protect the vehicle's painted finish.
NOTE:
Tape only provides minimal protection and extreme care needs to be taken when using urethane cutting tools.
Remove the seven sunroof spacers (1).

Fig 8: Common Glass Tools Needed To Remove Sunroof Frame
Courtesy of CHRYSLER GROUP, LLC

Common glass tools needed to remove Sunroof Frame
- 1- Extractor® Express™ or equivalent, equipped with flat blade
- 2- Two handled wire type cut out tool
- 3- Cold knife equipped wit a 25 mm (1 in.) blade
- 4 - Cold knife equipped with an 38 mm (1.5 in.) blade
- 5 - Long knife
Fig 9: Flat Blade & Sunroof Frame
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Take extreme care not to bend the sunroof frame during the removal process. If the sunroof frame is bent, it will be necessary to replace the sunroof frame with a new service component.
Using an Extractor® Express™ tool or equivalent, equipped with a flat blade insert the blade (1) under the front of the sunroof frame.
NOTE:
Be certain it is under the sunroof frame and not the sunroof header panel.

Fig 10: Urethane Front Bead & Full Perimeter Urethane Locations
Courtesy of CHRYSLER GROUP, LLC
Cut the front bead (1) of urethane across the front of the sunroof frame.
Using the same tool, only cut front edge of the perimeter bead (2) of urethane across the front area of the sunroof frame.

Fig 11: Cold Knife & Rear Corner Of Sunroof Frame
Courtesy of CHRYSLER GROUP, LLC
Insert a cold knife (2), equipped with a 25 mm (1 in.) blade into the exterior rear corner (1) of the sunroof frame.

Fig 12: Sunroof Frame Exterior Rear Section & Sides
Courtesy of CHRYSLER GROUP, LLC
Use the cold knife, equipped with a 25 mm (1 in.) blade to cut the urethane along the exterior rear section (1) and along the sides (2) of the sunroof frame.
Use a cold knife, equipped with a 38 mm (1.5 in.) blade to cut the urethane along the exterior rear section (1) and sides (2) of the sunroof frame.

Fig 13: Sunroof Frame, Roof Flange & Cold Knife
Courtesy of CHRYSLER GROUP, LLC
From within the interior, insert a cold knife (3), equipped with a 25 mm (1 in.) blade between the roof flange (2) and sunroof frame (1) at the front of the sunroof frame.
Use the cold knife (3) to cut along the front edge of the sunroof frame.
Repeat along the interior rear edge of the sunroof frame. Do not repeat the cut with the cold knife, equipped with a 38 mm (1.5 in.).
If the sunroof frame is still bonded to the point of not being able to lift the sunroof frame easily without causing damage, insert a the cutting wire for a two handled wire type cut out tool and manually cut the remaining perimeter bond. If sunroof frame lifts easily continue to the next step.

Fig 14: Long Knife
Courtesy of CHRYSLER GROUP, LLC
Lift the sunroof frame up slightly and use a long knife (1) to cut any remaining urethane.
With the help of an assistant, lift the sunroof frame to verify all of the urethane bond is completely severed.
Lower sunroof frame back into position.
Inspect to be certain the sunroof frame sits completely and evenly upon the original urethane bead on the roof flange. If the sunroof frame does not it must be replaced.

Fig 15: Sunroof Spacers & Masking Tape
Courtesy of CHRYSLER GROUP, LLC
If reusing the original sunroof frame-
1. Replace the seven sunroof spacers (1) previously removed.
2. Connect the battery negative cable.
3. Connect the sunroof wiring connector and sunroof switch.
4. Install the sunroof glass. Refer to GLASS, SUNROOF, INSTALLATION .
5. Close the sunroof fully.
6. Disconnect the sunroof wiring connector and sunroof switch.
7. Disconnect and isolate the battery negative cable.
With the aid of an assistant, remove the sunroof from the vehicle.
Remove the masking tape (2) from the sunroof opening
Inspect the sunroof opening for paint and sheet metal damage.
If body repair is needed, repairs must be made prior to sunroof frame installation.