I’ve recently purchased a 1983 XJ6 series 3 and the sunroof had two main issues I’m trying to resolve:

1. when fully closed, the rear part of the exterior panel was not sealing with the roof (too low & cracked/brittle seal
2. when opening and closing, it stops in three different spots in its full range and makes a clicking sound (gear seems to be skipping on cable teeth) and I have to manually, with my hands, move the sunroof just enough to gear to properly engage with he cable and move a bit more.

With some adjustments, I’ve mostly solved #1. BUT now I am really struggling to install the new seal on the rearmost track. Does anyone have any pointers on how to slide this rubber seal into the metal track on the sunroof exterior skin? I tried wd40 and dawn to lubricate the track... but it didn’t do the trick. Appreciate any guidance!

 

to fit the seal to the rear side of the sunroof panel, insert one side of the seal into the side of the channel nearest the painted part of the panel. No glue or adhesives.

apply olive oil or transmission or power steering fluid or engine oil to the bottom of the other edge and using a helper tool that does not have a sharp edge that may cut the rubber, start pushing the seal edge into the channel. I use a thin slat of wood.

as to the slipping of the cables at the motor worm gear, it means the gear is worn and no longer bites onto the cables.

Contact David at Everyday XJ for a motor with a better gear. There was a replacement gear assembly available but finding one is another story.

 

Jose, thank you very much for the helpful guidance! I will try this approach (vs sliding it down the channel, which was not working)... but hoping you can help me with two more questions...

1) You use a thin slat of wood.. how wide is it (the surface that mates with the rubber)? I assume about 1", but prefer to follow the path that's worked for you in the past.
2) Do you have a preferred grease to use on the worm gear?

Thanks again!
Nick

 

you're welcome Naber

any tool or wood slat I use needs to be very thin but blunt because you need to push the seal into the channel by compressing the seal using the thinnest part of the seal, or the "neck" of the seal, to compress it while pushing it into the channel. By THIN I mean 1/16" Inch or less thin.

Example: a putty knife is perfect but it is too sharp and it will cut and damage the seal. It needs to be something that will not cut through the rubber as you push the base of the seal into the channel.It also needs to be strong.

Also you can lube the base or "foot" of the seal with Vaseline / Petroleum Jelly so it will slide easier.

Any general purpose grease will work for the motor gear, even Vaseline. Not much is needed anyway. Too much grease and it will liquify and drip down.

 

I used a little silicon spray on the seal and then the end of a popsicle stick to push it into the groove. It worked pretty well and didn’t damage the seal.

 

A popsicle stick is very similar to the device I used, a generic auto body/panel tool.

 

perfect! a popsicle. great idea.

I remember PAYCO.