Any Sunroof experts? Broken slider/lift arm attachment at rail

[red740is]

I am hoping someone can help point me in the right direction on this... I am numb right now, spending the week redoing my headliner, sunshade and all pillars (in black!), the very last step of my reassemble was to put the sunroof glass back in.

Not a good day, as took a break from the headliner project to attempt the pixel fix on my cluster - another fail, another story.

Anyway back to the sunroof; Easy enough, 3 screws on each side then some adjustments. Well, in the processes of operating it to check adjustments, this part broke:

BMW2.jpg

I've been looking and poking around but am not coming up with much on how to replace it or if I need to take the headliner out again to even access it via the cassette. I found a part on realoem called "sunroof control rail" pn# 54128209795, but there isn't enough detail in the pic to show if it includes the broken pary. The broken piece in the slider mechanism is the part that moves back and forth to open and close the glass.

Here's a pic from the side that's not broken
BMW1.jpg

I really hoping someone out there can offer some insights on fixing this.. this car has really worked me over the past few weeks with various issues.

Thanks

[740ilDuke]

This was me 100% in May. The best thing to do is drop the headliner and replace the entire mechanism/pocket. Now I have all black, except the
sunroof slider, and I promise you I will never do that job again. I'll be letting a shop recover that panel. I got a quote in the aftermath from a local
shop of $600 to do it all, and honestly I kinda wish I had. But, I only spent about $100. Luckily a friend gave me the replacement sunroof. The entire pockets sell for about $100-200 on ebay. Mine ripped the arms off the track when I reinitialized, I was livid.

Here one exactly like what went in my car. I will say that replacing it was very easy.

https://www.ebay.com/itm/BMW-E38-740...frcectupt=true

[Sundaycruzer]

Part can be replaced without dropping headliner. It’s a job for sure but I’ve converted 2 metal roofs to glass which requires the removal of both slides to retrofit. So yes it can be replaced without removing entire assembly. Part number is 54128173106

[red740is]

Duke and Sunday, thanks for your replies! My headliner came out awesome, used flat knit black.. will post a pic. Mine snapped during initialization as well.. I think the lesson learned here is to hand crank it closed first. I'm trying to avoid taking the headliner out again if possible as I just finished putting it in, so if theres a way from up top, I'll attempt that first. My cassette is in otherwise good shape as a low mileage garage queen.

Sunday: would you mind sharing how you got that part out of the rail? Great to know it's replaceable and thanks for the PN#.

I took the stops out at the front if the rails and hand cranked it forward.. seemingly its attached to the cable and am wondering if it could be slid out the front with wind deflector detached? Thinking also that maybe I should remove the motor so I can slide and move things easier.. I just dont want to break anything else!

Any insight appreciated!

[Sundaycruzer]

Sunday: would you mind sharing how you got that part out of the rail?

There’s a tone of screws, and you have to pull the motor. The most frustrating part is aligning the cables it takes a few try’s to get them in perfect alignment. Basically take everything that can be unscrewed off, then you push the cables too the front of the car. There is a section of trim that gets removed were the plate or mount on the end of the cable can be removed from its track in the sun roof housing. Then you pull it toward the back of the car to remove. Then repeat to install. I found the best way to align is to make a jig from the good side to get the distance aligned between sides whatever you do try to leave the good side alone so you have a reference. Hope this helps.
Steve

[red740is]

Thanks for the details Sundaycruzer. I ordered the part and will give this a shot. Surprisingly there isn't a lot of info about these types of repairs out there. If all else fails I just get a used cassette but I'll be giving this repair my best shot.

[Sundaycruzer]

Thanks for the details Sundaycruzer. I ordered the part and will give this a shot. Surprisingly there isn't a lot of info about these types of repairs out there. If all else fails I just get a used cassette but I'll be giving this repair my best shot.

Your a bit to far away for me to fix. There’s no info that I can find if you get stuck pm me

[chrisn7]

.

Here one exactly like what went in my car. I will say that replacing it was very easy.

https://www.ebay.com/itm/BMW-E38-740...frcectupt=true

The image in the link is useful for anyone wanting to know about the sun roof drains and their locations. You can see why care is needed when attempting to clear blockages, as the hoses at each corner are not clipped, but merely pushed on.

[red740is]

Your a bit to far away for me to fix. There’s no info that I can find if you get stuck pm me

Much appreciated!

[Sundaycruzer]

Much appreciated!

If I pull out the computer some time this week I’ll look st my ista and see if there’s a work sheet on the sun roof

[red740is]

Thanks for that and your willingness to help! I actually got the broken slider out and am just now waiting for the new part. Needed to disconnect and remove the front deflector linkage, remove the metal end cap at the front edge of rail where cables come in from below and remove the motor. I then slid out the front sliding hinge, plastic carrier that bellows attaches to and then the control arm slider. There's just barely enough room to slide them out.

With the motor removed, I operated it till it stopped by pushing the close button, then tilt, which is where I will have the arms positioned to re-install the glass. This go around, I will not attempt to operate the switch to close the sunroof before adjusting and re-initializing, I will hand crank it to "closed". Then press close button to 20 sec or so to initialize that position, then open initialize, etc.. Fingers crossed it will go better this time!

If there is anything wrong with my intended process please let me know.. I have gained an understanding now of how this thing works and operates but still fuzzy on getting the initialization and synchronization just right, but at least there's some documentation out there on that vs the repair info.

[740ilDuke]

Good luck with it!

[red740is]

Thanks Duke! Here are some pics of my headliner that triggered this mess:
20181106_163443.jpg

20181106_163425.jpg

20181106_163509.jpg

20181106_163412.jpg

In the end, I think it will be worth it.. I love the black headliner! the $600 you were quoted was a deal. I priced it before doing it as I knew it wasn't going to be fun. I was quoted $1200 and that was with me doing the removal and installation work, although it included A, B, C pillars but NOT the sunroof shade (was going with OEM grey at that point)

[740ilDuke]

That handle snaps out, carefully - if you want to paint/dye it black. Yeah, I love the black in mine too. Just that pesky piece left to deal with. LOL. Currently all black fabric less the slider.....looks le' terible'.

Hope you get it back together!

[red740is]

Yeah, I thought about painting that and had it off to do the recovering, but I left the grab handles and visors and lamp housings gray, plus I was worried about the paint wearing off from handling and use. I did paint the little screw covers on the A-Pillars though.

Also happy to report it's all repaired and fixed 100%. I'll admit I've been lax sunroof maintenance of cleaning and lubricating in the past, but after this and cleaning the hardened grease and other "stuff" on all moving and sliding parts, I'm going to be more diligent about that and on my other 3 cars with sunroofs.

If anyone ever needs to do this or a similar repair, here are some tips:

Know that all sliding parts in the track can be removed from the top.. although it takes a bit of finesse to work them out.

The front caps that cover the cables need to be silicon-ed on the outer edges to prevent water from breaching that area.

Use proper sunroof grease! Everyone has an opinion, but I went for a $30 tube of VW/Audi Sliding Sunroof Lubricant. Other stuff will work, people say Sylglide is a good option, but I'd rather stick with what is used from factory/at dealer. Most of these cassettes are made by Webasto and ALL of them are metal and plastic, so a specific branded one shouldn't matter. I also have 2 Mercedes with sunroofs and an Audi with one, so the goal was 1 product for all. VW's was the most product at the best price.

On reassembly of everything (with sliders aligned), put the motor in and use the allen key to hand crank to tilt. Then remove motor run it to open, then close, then tilt. Reinstall motor. Push and hold tilt button to initialize (20-30 secs, wait till click or slight movement).

Then reinstall glass. Close, adjust glass. Operate and check function. I did another initialization/reset in the fully closed position just because.

[740ilDuke]

Fantastic work. I do want to get some grease so that tip is very helpful. Sadly, I've never greased mine beyond a little lithium. I've got 2 E38s so, this will be a priority.

Pop down to NC and remove my slider, would ya? haha

[waloch]

Hi,
I found your post from 2018 about repairing the sunroof slide on a BMW E38. Could you describe step by step how to fix it? Do I need to unscrew the sunroof motor and manually extend the mechanism cables? I’ve managed to disassemble most of it, but the part that broke (the same as in your case) is still left, and it works together with the cables. Thanks for the information! Best regards.

[Runnyzworld42]

I’m also in need of help with removing the rear guide rails I have everything else out but those last 2 pieces which I’m afraid of breaking it