|Here is one
procedure to replace the moonroof seal on your 35th.
After a time the seal will shrink and allow the ends to
gap letting water and air seep through. Try to install
the seal in the shade and with the temperature at least
George Davenport, of the SuperCoupe Club of America, has
found the moonroof seal at :
Webasto order desk: 800-860-7866
Part no: S1590-E-5010C-A (as of January
2002), Starlite-6 Gasket Assembly
(Old Part no: S1286-D5010A)
Price: about $40
Thank you, George. (Ford's price for the seal is not
something you want to know. )
To remove the glass
1. Run the glass rearward not quite half way.
2. Unsnap the black plastic rim (or halo as it is called
in the manual) that surrounds the glass by pulling down
gently on the edge toward the front
3. Operate the moonroof to raise the glass to the vent
position. (rear edge up. ) then slide the halo rearward
into the area behind the opening and out of the way.
4. Remove three phillips screws on the left side of the
glass and then the right side of the glass.
5. From outside of the car, carefully lift and remove the
glass from the frame.
Now place the glass on a soft working surface with the
top side up and you're ready to do the seal.
Remove the seal from the glass and thoroughly clean the
metal channel where the seal goes.
To insert the new seal, begin inserting the new seal with
the end starting on the passenger side of the glass. Be
very careful not to stretch the seal as you install it.
Apply weatherstrip adhesive to hold the seal at points
along the channel, particularly at the corners. I found
the seal to be difficult to hold it's shape at the
corners without using adhesive to keep it there.
Patiently work the seal into place around the channel
until you are about 2 to 3 inches from the beginning
edge. At this point, you need to keep in mind that the
seal will shrink over time. You need to cut the seal at
least 1/16th of an inch longer than where it will meet to
the beginning edge. At the beginning edge, slip the other
end of the seal into the channel and butted up against
the beginning edge. You will then have to work the seal
backwards the way you came and mold the seal to fit down
into the channel. Let the adhesive cure for a short time
and you're done.
To replace the glass
1. Operate the moonroof to lower the glass frame about
1/4 of the way.
2. From outside of the car, position the glass into the
frame and install the phillips screws finger tight on the
center ones and tighten the outer ones.
3. Lower the glass panel down into the roof opening and
then just where the glass drops below roof level. (NOTE:
Do not let the glass travel rearward or you might damage
the plastic halo.)
Then raise the glass back up to stop at the flush
4. Adjust the glass as necessary for fit and then tighten
all phillips screws.
5. Slide the plastic halo forward to it's proper
6. Operate the moonroof glass rearward about 1/4 of the
way and snap the halo back into place.
Now you should be done and
the glass should seal. Remember to keep the remainder of
the seal you have left for spare in case the seal shrinks
with age and you can cut a piece to fit into the gap.
I have tried to be as
thorough as I can. This is how I did it according to the
factory shop manual. I hope you find this helpful.