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Sunroof gear replacement

32K views 107 replies 9 participants last post by  voxmagna 
#1 ·
So my eos has the common sunroof gear worn issue. I have a replacement. I will be regreasing the tracks as I suspect poor lubrication is what caused the worn gear in the first place. Is the sunroof removable by hand cranking the motor.
Or am I better off just spraying some lithium grease on the tracks in situ while cycling the operation of the motor by hand cranking?
 
#106 ·
I think somebody with a decent home workshop is making them in brass for around £100, search Fleabay. But IMHO it's not the nylon cog that causes the failure, it's the end result and that's the warning given by all those selling them. Here's a quote from one of my recent posts:

Here's an example which I haven't needed to prove of what I think may be the root cause of serious sunroof failure and as a consequence, further collateral damage which could total an EOS roof: The sunroof motor has huge torque but the lowest torque (and motor current) will always be when the sunroof slides square and true in its guides. The sunroof frame is pushed and pulled by the infamous Octopus Bowden cables. The sunroof motor and drive mechanism isn't much different to other VAG cars. BUT the EOS Moonroof is much larger and heavier. They use much the same parts, but reduce the motor gear ratio.

From now on, the lower gearing gives even greater torque on the sunroof motor gearbox and its nylon gear. When that fails, everybody goes for the quick fix of a replacement nylon motor gear and rail greasing, only to have the same problem return. The Bowden cable is constructed of an inner wire with a semi-spiral running along its length which is its rack & pinion equivalent to a gear. The gearbox motor gear meshes with this spiral to push or pull the wire attached to each end of the sunroof tray carrying the glass. Once the motor is assembled you cannot easily see the quality of the mesh, any breaks, gaps or weakness in the spiral gear along its length where a 'tooth' could jump. My theory is the Bowden cable can exert an uneven pull or push on one side of the tray when the spiral is broken or deformed. This is a huge disaster because the tray will never run square in the guides, however much you grease them. We should accept the repair procedure carried out by V.W which is to replace BOTH the Octopus cable assembly AND the sunroof motor together. Pay up or write off your EOS roof - that's your choice
 
#108 ·
AFIK the roof top sections forming the sides of the sunroof frame and holding the guides have to be removed. But alignment service tools are required. It's specialist work, even with a shop manual which you should read very carefully before doing anything.
 
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