Front Sun roof leak repair with pictures

rmacaul · May 31, 2009

I have looked around all the sites and could find lots of threads on sun roof leaks but none with pictures.
I don't know about you but a photos is a help.
Here goes.
Nice sunny day perfect for sorting my leaking sun roof.

First of take the trims from the A and B pillars.
Take the grab handles down 7mm socket.
Un-screw the sunvisors and pocket with the sun roof switches/light.
Sunvisor clip was a wee pig getting the cover trim of take care

:doh:
Pull out the allarm sensor above the B post.
Take the trim of the sun roof hole

The head liner should be free pull it down about 6" go easy.

You can now see the drain hoses, I put water into the sun roof now and saw that the drains were ok it was the plastic fittings that were leaking just small drops hitting the head liner from both fittings.
I took some semi setting sealer and applied it round the plastic, this takes time to dry but skins in 10 mins.
I took the time to remove the hoses ends and flush water down them to make sure they were clear.

As the book says refitting is the reverse of strip down, Total time for the whole job about 4 hours including various tea breaks.

Waiting for rain to see if I can take this one from the list.

Hope this may help someone else

Headtester · May 31, 2009

Nice one thanks - I was planning to do mine this weekend but had too many other "duties" to do - ferrying kids and ponies to horse shows. BTW there is also this guide on leaky sunroofs.

PASTMASTER · May 31, 2009

Lots of pics on Discovery Sunroof Guide

PASTMASTER · May 31, 2009

PASTMASTER said:
Lots of pics on Discovery Sunroof Guide

Sorry - duplicate link there.

rmacaul · Jun 14, 2009

All is going good on the sunroof front north of Scotland has had a few very very wet days and the inside of my disco is dry. so much so that I have now installed my DVD player with out problems. it was a bit of an ass nipper cutting the head lining and drilling for the nut rivets but all came good in the end.

Blueskijay · Feb 8, 2011

My definitive answer to leaking sunroofs, wet floors at b pillar drips from sunroof handle etc etc.
The only way is to set aside 5 hours or so, get yourself a tube of black marine sealant - sikaflex £8 from fleabay (silicone is great on baths....) and set to:

Take out the entire headlining - plenty of threads on how do this, get it out of harms way and lay the seats down.
Then take out both sunroofs via the dozen or so tork bolts.
Check each drain tube there should be 2 per roof, the plastic collector should be sealed all round with your sealant and the tubes should be blown through.
Refit the sunroofs having first applied a thick bead of sealant to the roof skin on the outside. Bed the sunroof down on this.
Then remove the roof bars and give a generous squeeze of sealant all round the roof skin and also between sponge 'seal' and roof bar itself.
If feeling flush fit new sunroof to glass lip seals. Or vaseline them for budget option

Put it all back together
You can spend many happy hours and partial headlining removals trying to track down the leak. Or you can go for it and seal all possible routes for water entry in one go whether it is the actual source or not. Ask me what in hindsight, I think is best.:doh:

The Mad Hat Man · Feb 8, 2011

well?

rmacaul · Feb 11, 2011

Well what!

it is a disco it still leaks!

seriously all was dry for a few months then the carpets were getting wet again. weather up here has been s**t so just ran some silicone round the outer edge of both roofs it has been dry now for a month. I will order up the seals when the weather gets better.

discool · Feb 12, 2011

Only a few discos mentioned on Forums leak, there's thousands that dont.

rmacaul · Feb 12, 2011

I think you might be wrong.

people who say they have no leak just have not found it yet

discool · Feb 12, 2011

rmacaul said:
I think you might be wrong.

people who say they have no leak just have not found it yet

13+ years and no leaks mind u I only open them once a year for a bit of TLC maintenance

They rattle at speed when open so a bit naff

cornwallphil · Mar 21, 2013

Absolutely right. Most leak. Just removed headlining on a 53 Disco TD5. The two motors were full of water. I think they will probably work after they are cleaned up. Roof to sunnroof seal isn't great. Got them out and will bed on sealant. Drain tubes are not blocked but broke pipes getting them off end of sunroof fittings. Resealing end units and refitting a pipe connector shouldn't be a problem. I agree with ot saying do it all. Most of the set up is rubbish so you might as well pro actively fix the lot.

robbh · Mar 21, 2013

Weld em up job done! Forever!

That's my plan anyways!

acwsj · Aug 16, 2013

I thought my sunroofs were leaking (water dripping down round the rear view micro) and replaced the front roof seal. No improvement. Then took out the headlining and found that there was a noticeable dip in the windscreen sealing right in the centre of the screen. I put black sealant under the top outside windscreen trim (as much as I could get in) and the problem has disappeared.

Front Sun roof leak repair with pictures

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