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2003 chevy trailblazer_lt
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Discussion Starter #1 (Edited)
How to repair sunroof.

Vehicle used for documentary: 2003 Chevy Trailblazer LT (other vehicles may have slight difference's)

Symptoms:
loud snap or bang while opening or closing sunroof
unable to close or open sun roof

How to prevent:
clean and grease track regularly, grease that came with repair kit looked like axle grease

Parts needed:
ordered repair kit from http://www.sunroofdoctor.com at time of writing cost is $119.00 (no part number must search by vehicle)


copyright stock image from www.sunroofdoctor.com of said repair kit

Tools needed:

Socket set
Torx set
Pliers
Flat head screwdriver
Rivet Gun
Towels
A friend is recommended for some parts

OPTIONAL STEPStep 0: Remove glass
I found it easier to take the assembly in and out easier with the glass removed.

To remove glass: 2 small torx screws on each side of sun roof opening from inside of vehicle. Picture is of driver side screws.



Step 1: Drop head liner processes vary vehicle to vehicle
To drop the head liner, following items need to be removed:
A pillar
B pillar
c & D pillar
Coat hanger hooks in trunk roof
Trunk light cover
2 plastic pull clip next to trunk light
4 over door grab handles and light covers
2 sun visors (was a huge pain for me)
Center roof console

After all that is removed the head liner can come down. It is attached to roof with velcro in some areas. the head liner MUST come straight down and sit on top of the seats. There are electrical wires hot glued to the roof liner with no disconnects. So pulling the head liner out all together would require alot more work.

Step 2: Removing Sun roof assembly
This is when the extra hands come into play. As its a bulky item trying to carry out over the head liner. From front to back in the photos.

2 small bolts at front of sun roof near winshield


Disconnect plug to electrical motor as shown in 3rd picture below. It is located at the rear of the assembly.
There are 2 drains per side to disconnect. 1 in front and 1 in back, they just pull off, no mechanical fasteners.
Remember how the plastic pin is positioned, as i found this helpful for re-aligning the frame when ready to install back in.
There are 4 bolts on each side as circled below that need to be removed.




Step 3: Dis-assembly of motor
The motor needs to be removed in order to complete repair.

Assembly on table. Unit is upside in picture.


As with any project, do one side at a time.

First part is to remove the bolt circled near the rivets. With that bolt removed the galvanized channel can swing out of your way.

Second Part is to remove 3 rivets located at rear of assembly. They need to be drilled out. Drill size is specified in directions that come with repair kit.



With rivets removed, carefully release the plastic cover that was attached with the rivets. There is some caulk? material holding it down. Again be careful as to not damage this part.



Third part is to remove the motor. 3 torx screws hold it on.


With motor removed.


Step 4: Removing damaged parts

The unit will need to be flipped over. Now the rear drip tray needs to be removed. I believe there is 1 screw on each side to remove it.


Next part is to remove the traveler (pictured below). It will be easier to remove with the motor no long attached.


As you pull the traveler out you will see this coming out of a black tube on the other side. Do not be alarmed, it is just the extra cable from the traveler.


In order to get that parts off you will need to push down a little nub in the track designed to stop the parts. I used a hammer and a screw driver to push it down enough to slide the parts over. YOU MIGHT NEED TO DO THIS STEP BEFORE PULLING OUT THE TRAVELER I dont remember


Now for the damaged parts. BEFORE OR AS YOU PULL THEM OUT REMEMBER HOW IT GOES AND MATCH IT TO THE NEW PART TO INSURE IT GOES BACK TOGETHER RIGHT The pictures here cant show you perfectly how it goes.

But here is what i saw on my passenger side. Clearly damaged.


Slide the parts off once your sure of how it goes together.
 

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2003 chevy trailblazer_lt
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6,568 Posts
Discussion Starter #2 (Edited)
Step 4a: the parts

Here are pics of the new parts next to the old.



And the culprit of it all. Broke into 3 or 4 pieces.



CLEAN AND REGREASE TRACK

New parts installed. Reverse of tear down.





Step 5: Aligning the brackets to proper position.

The directions go over this with you also. You use a 1/8" drill bit(?) and slide it through a hole in the 2 parts below to place the brackets in the proper closed position. I recommend checking this a few times including before you put it back in the truck.



Step 6: Repeat on other side

Step 7: Reinstall motor
Reinstall rivets removed earlier.
Reverse of removal.

Step 8: Install assembly
Reinstall assembly into vehicle.
Reinstall glass.
Follow memory relearn procedure and test a few times.

Step 9: Put vehicle together



Extra notes
Motor Information






Many thanks to Tyler (Chevy-TB-lover) for his help on the tear down and reinstall, the pictures, and the use of his shop.
 

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Premium Member
2003 chevy trailblazer_lt_ext
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268 Posts
great job, I will subscibe to this thread for future reference, as the dealer had to change mine twice......the rivits you removed, did you replace them with bolts and nuts?
 

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2003 chevy trailblazer_lt
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6,568 Posts
Discussion Starter #4
great job, I will subscibe to this thread for future reference, as the dealer had to change mine twice......the rivits you removed, did you replace them with bolts and nuts?
no.. the repair kit comes with new rivets... so i put the new rivets in...

the kit comes with the 6 parts, the rivets, directions, 2 swabs, and a container of grease... by far the best complete kit ive ordered to repair something...
 

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2002 chevy trailblazer_ltz
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86 Posts
holy geeze complicated but thanks to these pics im gonna give it a go. here goes nothing.
 

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2003 gmc envoy_slt
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1 Posts
Sun roof module programming

For reprograming of the module perform the following procedure:

1) Put the sunroof in the fully closed position
2) Press the open and hold the button until you hear the motor make a sound (this takes 30-60 seconds)
3) Then you should be reprogrammed and roof should operate normally

This procedure is what worked best for me I hope it helps
 

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2002 olds bravada
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82 Posts
Awesome write up!!! You just reminded me I have to clean and grease my track before winter.

:thx
 

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2002 chevy trailblazer_lt
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141 Posts
nice write up i have to get this fixed on my tb, the part that pulls the glass back broke ( not sure if its the same one as your dont remember ) and when i drive around 65 or more or on windy days the glass lifts up a bit and is kinda annoying.
 

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2004 gmc envoy_slt
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538 Posts
come help me fix mine....mine did the dip thing in the corner and goes crooked during operation and jams....i just shoved it back into place so it wouldn't leak...I never heard a snap or anything though it just happened
 

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2003 chevy trailblazer_lt
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Discussion Starter #13
Location: Chesapeake, Va

sorry outside of my range lol unless u plan on coming to chicago... lol
 

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2003 gmc envoy_sle
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5 Posts
Why is my sunroof different than this one. I have a 2003 Envoy SLE and my sunroof shattered and i got an envoy/trailblazer sunroof and its like this but is like 2 inches smaller than mine from side to side but is the same front to back. do any of you know why mine is different and how i would find the right sunroof glass to replace it?
 

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2004 gmc envoy_sle
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1 Posts
great sunroof repair post!

04 envoy, broke just like the pics. Headliner down, sunroof on the bench ready to install new parts. It's getting late so I'll attack this again tommorrow when I'm not so tired.:sleepy: Thumbs up to sunroof doctor, great customer service and fast shipping! I'll let you all know how it went when I'm done!
 

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2005 gmc envoy_slt
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95 Posts
Holy Crap...i've been working on this all day....found a busted piece of plastic in the passenger side rail. It sucked cause it was a beautiful day and all I wanted to do was open my sunroof.:( Heard a snap and that was that...wouldn't close all the way again and the more i tried, the more it ripped the seal on the glass. I've pulled the liner and now i'm down to two screws to pull of the frame. Thank you very much for the write up...the pictures showed me what part broke before I even pull the frame. Going to see about getting the rebuild parts now....since gm direct want 500+ for the part. I don't think they will sell the pieces individually...looks like just the frame. Thanks again:thx:thx:thx
 

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2005 gmc envoy_slt
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95 Posts
Ok...so I repaired all the broken parts on the sunroof and put it back in. I tried to relearn the positions but the motor doesn't stop...it almost crunched the new parts with the torque. I took the motor off and it will open but won't close. The motor was working fine originally so i'm thinking I might have done something wrong while i was reteaching it. Is there any way to clear it??? If I just hold the button to open, it runs continuously for 30 seconds and then shuts off. If I try to close, nothing.:confused: any help would be much appreciated.

Thanks
 

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2005 gmc envoy_slt
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95 Posts
I've just tested to motor and it will turn both ways with an external power supply so it's not the motor....i'm lost at this point.
 

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2003 chevy trailblazer_lt
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6,568 Posts
Discussion Starter #19
hmmmm i'm not sure... when i did mine i didnt have to do the relearn. it wouldnt do the relearn correctly but it worked fine when i put it back in. so i'm lost to... maybe disconnect the battery and try again. but i have no idea... sorry i'm not much of help in this spot.
 

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2005 gmc envoy_slt
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95 Posts
Ya...i think i might have to take it down to the dreaded dealer:sadcry: and have them reprogram it. For now though, I have it exactly closed position and the glass on so until I get time to take it down....only issue is that the roof is still gutted.:duh:
 
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