I didn’t get around to writing this out at the time, so just
now catching up on old topics.
These instructions are a supplement to the JTIS which I
found to be inadequate.
I got the repair kit from www.sunroofdoctor.com for Lincoln
LS, which is the same 6 parts although the instruction page
lead me to suspect the Lincoln is slightly different.
Tools you need: Torx #10, 15, 20, 25 drivers, 8mm and 17mm
sockets, drill and bits, right angle screwdriver, cleaning
supplies.
First remove the sunroof glass, 4 Torx screws, then the
headliner. Pull down the rubber seal around all 4 doors; pop
off the covers on the front shoulder belt loops and remove
them with a 17mm socket; pull trim covers on A & B pillars,
they have spring clips so pull straight off, but C pillar
cover has a notch that fits into a post at the upper rear so
swing it down before pulling; pull out the rear overhead
lights, squeeze locking tab on connectors and unplug; using
the right angle screwdriver pop off the end covers on the 4
grab handles and remove; ceiling light panel pulls down at
the front, then push forward to release rear clips, unscrew
2 light switches, unplug connectors; pry off covers on visor
posts and remove screws but electrical connectors are glued
to the top side of the headliner; remove screws on visor
clips; pull off 4 corner hoses. I also removed the mirror by
pushing the mounting base downwards towards the wipers.
After all that the headliner is ready to come down. It is
held up by velcro pads around the sunroof hole so pull
carefully. I left the rear end in place.
Unplug big connector for sunroof motor. White plastic
ceiling light tray has 2 spring clips so pull straight off.
Remove 9 screws with 8mm socket. Lift sunroof mechanism out
front passenger door opening.
Cover your bench to keep the cover panel clean. Drill out 4
pop rivets at rear end caps, there is also sealant so pry
off carefully. Remove rear drip gutter. Slide cover panel
out and clean it. Remove motor and black plastic position
sensor gearbox. Slide out 3 mechanism parts, clean the
channel, slide in new parts, grease the channel. Set support
arm to closed position and put a nail through the alignment
holes provided. Same on other side. Turn the position sensor
over and turn the gear until a little alignment hole on a
white gear appears in the window, then reattach the sensor
and motor. Remove 2 nails. Reinstall cover panel & drip
gutter. Reattach rear end caps with RTV sealant and
#10-24X1/2 screws, lockwashers & nuts. Reinstall through
passenger door, 9 screws, redo big connector, test run but
watch lifting arms don’t pop out. If movement is wrong it
means the position sensor alignment was wrong. Reinstall
glass, test run again. Blow out 4 corner hoses and reinstall.
Reinstall ceiling light tray, headliner, two of my velcro
pads came off so I glued them on with Gorilla glue. Install
visors, grab handles, ceiling lights, pillar covers,
shoulder belt loops, mirror.–
XK120 FHC, Mark V saloon, XJ12L Series II, S-Type 3.0
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