Mechanics

SUNROOF

2004 Dodge Neon

Interior problem
2004 Dodge Neon 4 cyl Front Wheel Drive Manual 64400 miles

Hi, my sunroof was working fine until i noticed a codder pin appeared to be working its way out of the internal workings of the track/support attachment. I pushed this pin in until it was flush with the surface it was attached to. A few days later I noticed it wasnt closing all of the way so I pushed the pin back out to its original position and it still wont snug up the last little bit to close. The fastener is not droppinng down onto the stationary plastic nipple that allows the worm drive to lever itself closed. can I maybe get a blow up of the workings and parts and positioning of the factory sunroof so that i can figure this problem out?


http://www.2carpros.com/forum/automotive_pictures/411313_0919091651_1.jpg


http://www.2carpros.com/forum/automotive_pictures/411313_0919091651a_1.jpg


http://www.2carpros.com/forum/automotive_pictures/411313_0919091651b_1.jpg

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Avatar
Raynstorm
September 19, 2009.




http://www.2carpros.com/forum/automotive_pictures/46384_sunroof2_1.jpg



REMOVAL

Remove sunroof glass panel (4). Refer to procedure in this section.
Remove front locator 7 or 8
Disengage cable from mechanism (9).
Remove screws holding sunroof guide (5) and mechanism (9) assembly to sunroof module.
Lift assembly from module.
Rotate assembly to disengage wind deflector (13) from assembly.
INSTALLATION

Engage wind deflector (13) into guide (5) and mechanism (9) assembly.
Position assembly onto module and install screws holding assembly to sunroof module
Engage drive cable to mechanism.
Install front locator 7 or 8 . It may ease installation to move sunroof mechanism slightly rearward.
Install sunroof glass panel.
seperate components list
SUNROOF GLASS PANEL

REMOVAL

Position sunroof sunshade (4) in full rearward position.
Remove six glass attachment screws.
Push glass panel upward from underside until glass panel clears the roof panel.
Lift glass panel from vehicle.
INSTALLATION

Position glass panel (4) in opening in vehicle roof.
Install, but do not tighten, glass attachment screws.
With the aid of a helper, hold the glass panel in position and tighten glass attachment screws.
Verify the correct glass height.
SUNROOF CABLES

REMOVAL

1. Remove sunroof glass panel (4).
2. Cycle the sunroof mechanism to the full forward position. CAUTION: Do not remove sunroof drive motor unless sunroof mechanism is in the full forward position.
3. Remove sunroof drive motor (10).
4. Remove front locator 7 or 8 for appropriate sunroof cable.
5. Disengage sunroof cable from sunroof mechanism (9).
6. Pull sunroof cable from drive tube (2 or 3).

INSTALLATION

1. Push sunroof cable through drive tube (2 or 3).

Fig. 2 Front View Of Guide


http://www.2carpros.com/forum/automotive_pictures/46384__2_1.gif



. Engage sunroof cable into sunroof mechanism (9) making sure cable connecting rod is rotated at a 45 degree angle towards inside of vehicle.
3. Install front locator 7 or 8 over sunroof cable. Moving the sunroof mechanism rearward slightly will ease locator installation.
4. Move sunroof to full forward position.
5. Install sunroof drive motor (10).
6. Install sunroof glass panel (5).
SUNROOF SUNSHADE

REMOVAL

Remove sunroof glass panel (4). Refer to procedure found in this section.
Slide sunshade (11) to full forward position.
Disengage slide blocks on one side of sunshade from sunshade guide (6).
Lift and pull sunshade out of opposite sunshade guide.
INSTALLATION

Place sunshade with cloth side down and install one side's slide blocks into the track on the sunshade guide (6).
Slide the other side's slide blocks to fully inward position and insert them into the sunshade guide (6).
Verify that all four slide blocks are fully engaged in the sunshade guide (6).
Slide sunshade (11) fully rearward.
Install sunroof glass panel (4).

SUNROOF MODULE

REMOVAL

Remove headlining.
Remove fasteners attaching sunroof module vehicle roof and support braces.
With the aid of a helper, separate sunroof module from roof.
Remove sunroof module from vehicle.
INSTALLATION

With the aid of a helper, position sunroof module in vehicle.
Install fasteners holding sunroof module to vehicle roof.
Tighten all fasteners, starting from the front and working rearward and then the motor bracket.
Adjust glass panel for flushness to roof. Refer to glass adjustment procedure.
Install headlining.
Verify correct operation.
SUNROOF DRIVE MOTOR

CAUTION: Do not cycle the sunroof drive motor prior to installation. The drive motor is shipped in the closed position. The sunroof vent position is programmed into the drive motor and is dependent upon the drive motor closed position. If the drive motor and the sunroof mechanism are not both in the closed position, the sunroof vent height will not be correct.

REMOVAL

Remove headlining until the sunroof drive motor (10) can be accessed.
If the drive motor is to be reused, cycle the sunroof to the full forward position.
Disconnect wire harness connector from motor.
Remove the three screws attaching drive motor to sunroof module bracket.
Remove drive motor (10) from bracket.
INSTALLATION

With the aid of a helper, hold the sunroof glass panel in the closed position and engage the drive motor (10) into the sunroof drive cables.
Install screws attaching drive motor to bracket.
Connect wire harness to drive motor.
Install headlining.
SUNROOF WIND DEFLECTOR

REMOVAL

Open sunroof to full open position.
Pull one end of wind deflector flap out of the wind deflector beam (13).
Release corner piece locking tab and separate corner piece from wind deflector beam.
Rotate corner piece outboard to release tab from roof flange.
Rotate corner piece to a vertical position and pull it up through hole in guide (5).
Repeat for other corner piece.
INSTALLATION

Hold corner piece vertically and push tab down through hole in guide (5).
Rotate corner piece inward and place tab under roof flange.
Connect corner piece to wind deflector beam (13).
Install wind deflector flap into wind deflector beam.
Repeat for other corner piece.

Tiny
Mathiaso
Sep 19, 2009.
Thank you for the blow up of the 04 dodge neon factory sunroof, but it is a little small and if I could read it, it doesn't move to show me how it drops down that last little 3/4" or so. Can I start a dialog to start trouble shooting how to repair. I imagine removing the glass would be my first step in troubleshooting? I think that little codder pin is holding it back from dropping all the way down, but when I pushed it in flush with the "mechanism" (part item # 9), is when it stopped dropping all the way down. So I pulled the pin back to 1/4" outside of the "mechanism(part item # 9), but it is still not dropping down. :(


http://www.2carpros.com/forum/automotive_pictures/411313_0919091651_3.jpg


Tiny
Raynstorm
Sep 20, 2009.
What you need is to remove everything following this. No short cut check the mechanism 9 if it bent or worn out: REMOVAL
Remove sunroof glass panel (4). Refer to procedure in this section.
Remove front locator 7 or 8
Disengage cable from mechanism (9).
Remove screws holding sunroof guide (5) and mechanism (9) assembly to sunroof module.
Lift assembly from module.
Rotate assembly to disengage wind deflector (13) from assembly.
INSTALLATION

Engage wind deflector (13) into guide (5) and mechanism (9) assembly.
Position assembly onto module and install screws holding assembly to sunroof module
Engage drive cable to mechanism.
Install front locator 7 or 8. It may ease installation to move sunroof mechanism slightly rearward.
Install sunroof glass panel.
Seperate components list
good luck
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Tiny
Mathiaso
Sep 21, 2009.

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