I have a 2002 ford expedition with the sunroof and recently when I opened the sunroof I could hear like a metal plate rattle like if something was loose and now when I open it, it only opens about 3 inches. Anyone ever have this problem?

 

I had the same thing happen to my 01 the other day. Mine was the peice of sheet metal that causes the inner portion of the sunroof to open when the outer (glass) portion is opened. I had to use a flashlight and fish the peice of sheet metal out. It is the width of the window and about 3" tall. I have not figured out what I am going to do with it yet but at least the window works now.

 

I just removed that peice of sheet metal too and its been sitting in my garage not sure how to put it back on but it works without it so I will leave it off. I just have to open the cover with my hand now.

 

I went to the local dealer and got a picture of how everything lines up and the peice in question is considered a drain tray. We had a lot of rain and my roof began to leak. You can find the screws on either side near the back corner on the very outside of the small rod attachment point (you really have to look for them from above the window). You just have to loosen each side and the slots on either end of the drain tray slide in under the screws. When tightening you have to keep forward pressure on the tray or it will push out from under the screw.

Hope this helps,
MELMAN
Shore to Deliver!

 

Just did this repair on an 03 expedition at my dealership. To do it correctly, the headliner must be removed and the sunroof track taken out of the car and repaired, then reinstalled. It's quite a bit of work but well worth it. That piece of metal is called a water trough and needs to be there to guide water into the left and right channels where it then drains into hoses attached at the 4 corners of the track assy. Do an online search for TSB 03-11-10, which outlines the repair in detail. "Fixing" this problem any other way can, and will result in water damage to the interior, more extensive damage to the sunroof track and more than likely electrical problems down the road.

Good luck

 

I did a search on TSB 03-11-10 but could not find anything and its now leaking alot. How much did it cost to have the dealer fix it for you?

 

We have a 2010 f250 Harley Diesel. The sunroof will not close. It is opened in the back, not opened by sliding it all the open. I took it to the dealer this morning and they said the rails are broke. It only has 44,995 miles on it but it is past the 36,000 miles under which it would still be covered. My extended warranty, that we were told was bumper to bumper, does NOT cover it either. We are looking at $800 plus 5 hours of labor. Over $1000 to fix a sunroof we've only used half a dozen times on a $56,000 truck! They broke the plastic piece that holds it down so now they taped it closed so it wouldn't leak since it is raining here. Ugh!!! Anyone else experience thus problem?

 

I just removed that peice of sheet metal too and its been sitting in my garage not sure how to put it back on but it works without it so I will leave it off.