Front sunroof in my 03 td5 had been acting up but would always open /close eventually and as I had also some water coming into cabin from the roof dripping down at the middle front and now I notice after heavy rain some water at the drivers side floor towards the edge... I tried to shift the sunroof with an allen key (expected a much larger allen bolt considering the job it has to do) with the intention of a quick inspection and spraying the tracks etc. and then tackling the leaks ,but no joy..I assume now the only thing I can do now is to remove the headlining and the sunroof itself to free it up.. or has anybody come across anything stronger than the standard allen key what looks like a size 4mm ? Does such a tool exist? I'd like to do it sooner than later as it was working up to last week so don't expect a serious seizure .....

Did you just use a standard Allen Key? No use as not enough leverage.

Or an Allen socket on a decent size ratchet with extension bar.

Isn't it a Torx bolt?

alexdon said:

Isn't it a Torx bolt?

Click to expand...

If its same motor as TD5, I think its an Allen. Could be wrong though.

If you have electric operation you will have to disengage the motors drive, therefore the Allen Key should pushed hard in to the socket before turning.
Land Rover supplied a small key with an Land Rover embosed plastic handle as there's no leverage as such required.

My front sunroof wouldn't open when I bought my Disco 2. I made sure I knew what I was letting myself in for before I handed over the money To fix it I followed these steps.

1. Remove interior trim / map pockets to get access to motor assy.
2. Undo 3 torx bolts and electric connector to remove unit from car. (at this point I tried to move the winding mech with the allen key and it still wouldn't move)
3. Undo 3 torx screws to remove motor from gearbox. (try the allen key again, the gearbox on it's own should now move ok. If it doesn't then it's broken)
4. CAREFULLY take the motor assy apart and clean the spindle with the windings on it and the metal case. (the plastic bit with the wires shouldn't need cleaning. Make sure you clean the insode of the "nipple shaped bulge" at the end of the motor casing as this acts as a bearing.)
5. Carefully apply a little grease to "nipple shaped bulge" interior and put spindle back in casing. Put plastic bit back on (you will need to carefully move brushes out of way to do this) Once back together check that it turns easily.
6. Apply a little grease to the screw drive end of the spindle and put it back into the gearbox. Tighten up the 3 torx screws holding motor to gearbox (try using your allen key again. IT SHOULD NOW WORK!!!). You can now reconnect the electrics for a quick trial, but remember to disconnect again afterwards.
7. Using your now working allen key method, open your sunroof to the "tilted only" position. Take motor assy back off sunroof and ensure small notch in plastic timing wheel on gearbox is aligned with microswitch.
8. Carefully reassemble everything and try it out

However, if your sunroof is leaking, then you really need to drop the roof lining, strip out the sunroof and re-seal it between bodywork and black plastic frame. The reason your motor stopped working was because it got wet:doh:

Hope this all helps. If you look around you will find alot more info on sunroof's that leak

Thanks Erazmus/guys,good instruction & detail above ,will certainly go at this again when I know the weather might remain dry for a bit and you're dead right I need to tackle the leak(s) first as this is what probably caused the problem in the first place