Can anybody tell me how to remove and replace the glass seal on the Sunroof of my 1992 Pajero SWB.

Folks -

The "gearbox" is unfortunately under the headliner with no easy access. If you are also experiencing a clicking sound when the motor is activated, the regulator track had slipped position and will need to be reset.

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Removing the map light assembly (process below) may help in your initial diagnosis, you can feel the motor mounting screws and the motor assembly to determine if their loose.

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I have been through this problem twice now. The first time the motor / gearbox came loose from it's mounts, began slipping (click, click,click), very nasty sound. I remounted the motor with threadlock on the NEW ALLEN HEAD screws, but alas.. two years later (mine's 2006) it slipped again.. I need to drop the headliner once more and have a look. If you would like a copy of your 05/06 FSM, drop me a line.


Here's the RESET procedure from the FSM, absolutely gospel, no other way to fix it:

Sunroof Motor Assembly Note:

Note
• If the guide is removed, initial position setting of the sunroof motor will be required. After installing the sunroof unit, perform initial position setting using the following procedure.

1. Press the TILT UP switch to fully tilt up the glass panel.

2. When the glass panel reaches the fully tilt up position, temporarily release the TILT UP switch and press it again for approx. 13 s continuously. Continue pressing the switch until the glass panel automatically stops at the fully tilt up position after reaching the mechanical lock position.

3. When the glass panel stops at the fully tilt up position, temporarily release the TILT UP switch, then press it again within 5 s and hold.
Note

• Press the TILT UP switch continuously until the glass panel opens to the fully open position, returns to the fully closed position and then stops.

4. Release the TILT UP switch when the glass panel stops at the fully closed position.


ALSO, Here's the clearance adjustment specs for having the glass panel in the correct resting position:

GLASS PANEL ADJUSTMENT

1. Fully close the glass panel.

2. Measure the gap and height difference between the glass panel and the body.

3. Loosen the glass panel installation screws and move the glass panel to adjust.

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Standard clearance a: 0.2-2.2 mm {0.008-0.08 in} b: 0 mm {0 in}
4. Tighten the screws.

5. Insert any available thin plastic card between the weatherstrip and the body, and verify that they are sealed. (There is resistance when the plastic card is moved.)

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• If they are not sealed, perform Steps 3-4 and adjust again.

MAP LIGHT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Insert a tape-wrapped flathead screwdriver into the gap between the headliner and the map light.

3. Press the tab and remove the map light.

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4. Disconnect the map light connector.

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5. Remove the socket, then remove the map light bulb.

6. Install in the reverse order of removal.

SUNROOF UNIT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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1 Screw A
2 Drip rail
3 Sunshade stopper
4 Screw B
5 Sunshade
6 Deflector
7 Screw C
8 Sunroof motor
9 Rear drip
10 Guide
11 Decoration link
12 Front drip
13 Tape protector
14 Short cord
15 Frame