Did a search (on the Forum) and found nothing...so my apologies if this has already been covered.

Anyone have experience repairing their factory install sunroof? I recently purchased a used 4Runner, and after several weeks noticed that there is a significant amount of rust between the seal, and the metal (on the glass piece). There's no water leaking into the headliner or into the catch/drain holes, but I'd like to stop the leak and stop the rust (without buying a new sunroof glass assembly).

Initial thought was to pull the seal, sand/grind the rust, putty/JBWeld over the spot, and replace the seal. But I've not done this before.

Other option is to take to a shop/dealer, which I hear can run around $1200.

Any experience/advice? I'm going to call Carmax (since it's still under the 30 day warranty), but my guess is that they'll likely not cover "rust", even if it has resulted in a leak.

use silicon based grease on the rubber seal. I hate sunroofs. Hope you don't have to drop the headliner to fix yours.

Have not done this before. I can't visualize exactly what is rusted. If the rust is significant you might be able to use fiberglass+resin.

Make sure those drain holes aren't clogged. Rust in the sunroof shouldn't happen unless water stands there for a long time.

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I recently purchased a used 4Runner, and after several weeks noticed that there is a significant amount of rust between the seal, and the metal (on the glass piece).

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What year 4Runner? (I've got my friend's '02 sitting outside right now.) All I can see on his is a rubber gasket surrounding the glass and no metal. Maybe you're missing this piece?


[This message has been edited by p_bubel (edited 5/5/2010 10:30a).]

Thanks for the responses/suggestions - I can appreciate that it's a bit hard to picture, so I'll provide some detail.

The rust isn't in the sunroof water evacuation channel or roof sheetmetal, it's on the metal that is mechanically fastened to the sunroof glass piece, if that makes sense. The water evacuation drain/channel and holes are working fine, evacuating the small amounts of water that naturally gets between the seal and the body sheetmetal and into the water evacuation channel tubes...but the rust is on the sunroof glass assembly itself.

The glass assembly is made up of 3 things -- the glass, a metal frame that the glass is fastened to, and the seal that surrounds the glass/metal. The rust is on the metal portion, and has occurred due to water seeping in between the seal and the glass/metal sunroof piece. Water which never makes it to the drip channel (or makes it so slowly that the combination of metal/water/heat has resulted in rust. My guess is that most sunroofs, if you push the weatherstrip 'up' in the front, have some rust there.

So at this time, there's no damage to sheetmetal/ceiling/headliner, but if I don't address the seal and the rust, the problem will eventualy lead to more leaking, more rust, etc. which will one day either overload the normal water evacuation drains/channel.

The options I've thought about are:
A) Get a new sunroof glass (no rust, new seal, etc. but very $$$)
B) Get some adhesive to 'waterproof' where the seal/glass contact one another (stops water coming in, but doesn't address rust)
C) Pull the seal off, remediate the rust, epoxy/putty, replace seal
D) Run several small strips of duct tape around the portion of the seal which comes into contact with the top of the sunroof glass. This would stop any new leaking, while keeping the sunroof operable.

My preference is option C, but I've heard horror stories about the process it takes to pull a power, factory sunroof glass out (take headliner out, reset motors, etc.) Just curious if anyone on this forum has gone thru this.

btw...it's a 2005.

Oh, and I'm kidding about the duct-tape option (though it would likely work).

I'm bored so I went outside and took some pictures... maybe it will help, maybe not.


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It's just a random fluke that I have this 4Runner today. My Jeep is being borrowed, so I borrowed this thing...

[This message has been edited by p_bubel (edited 5/5/2010 12:39p).]

So is the rust here (see red arrow)? I see metal frame peeking out of the gasket.

dubi...those are great pics. I can take some pics when I get home, but those you posted help greatly. Thanks!!

In the second post, where you drew your arrow is exactly where the water is leaking in. From there, it stays trapped against the gasket and glass/metal, which has caused rust.

From what I can tell, most of the rust started behind the gasket and out of view (unless you push up the gasket in the front)...but it's rusted enough that there is rust on the bottom of the black metal from where it's eaten thru (the horizontal surface) on the front part of the sunroof.

I can re-seal the gasket/glass interface easily enough, but can't really take care of the rust without pulling the seal/gasket off....which probably means taking the glass compltely out..etc.

Harrumph.

Oops...sorry about that p_bubel. I got so caught up in looking at the pics that I forgot you posted the originals....so thanks for posting those!!!

I was basking in the unearned glory.....