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Leaking Sunroof fix writen by RallyRS (matt)

OK - I can claim to be very happy with myself on this one, but not before paying $800 to idiots to make it worse!!! Take the time to read this - it'll be worth it - mine has not leaked for over 2 years since I did this

Lesson Number 1 - DO NOT take it to a Subaru service centre - they will try to fix the leak through the hole in the roof by lifting the runners and stuffing it full of sealant - problem is doing this breaks the rest of the seal that you cant get to.

Lesson Number 2 - Remember that the rubber around the glass is ONLY a dust seal, it will let water through into the sunroof base... thats why the base has a drain in each corner. Dont get sucked in like me paying $600 for another glass (after paying the bill, the prick at Subaru told me that it still leaked!)

Lesson Number 3 - Clear each corner drain properly... the rear drains come out over the rear wheel, and the front come out behind the inner guard at the front. If these drains are blocked, the sunroof base will fill with dirt, water and general crap until it goes over the top of the runner and into the center section... then next time you brake heavy yot get a wet head!

So what am I crapping on about?

The Sunroof unit is a big steel tray with the glass mounted on runners that are in turn mounted to the tray. The runners are sealed to the tray using caulking compound... but after 10+years of heat and vibration the compound breaks up and allows water into the center. When sealed properly, the water stays on the outside of the runners and goes to the drain in the corner.
The ONLY way to fix it properly is to take the entire unit out of the car, lift out the runners and glass, clean up the crap, run 2 beads of windscreen sealant (not silicone - that causes rust) onto the tray and bolt it all back down again.

To take out the unit:
Open then sunroof (fully)
Remove Jesus straps, mirror, ligt, sunroof control, visors, front and rear seatbelt anchors.
Unclip all the dark grey velvet trims, unclip the headlining and remove.
Undo the wiring harness, the four drain tubes, the six bolts holding the sunroof tray.
Lower the unit onto your seats - then remove through the rear door.
Undo the for capped nuts holdingthe runners down. YOu may need to manually wind the glass backwards and forwards to get to them - the little handle for this is in the kit with your wheelbrace.

Dont think ive forgotten anything - PM me if you get stuck

Cheers, Matt