Sunroof odyssey

[longtallsally]

WOOHOO!  Well I must stand corrected then.  Good info on torque specs for the clutch too.

In terms of the relay and the stops, mine doesn't either and I think it is just catching everything and lining up correctly.  IMO I wouldn't bother.  You not only have to have the stop set up correctly, but the panel itself needs to be aligned in perfect conjunction or you will get wind noise.  By the stop not being there, it is easier to adjust while driving.  Without the bike rack on, mine is really quiet.  I think the panel is also perfectly adjusted, but I'm not taking it apart just to put the- to me- annoying stops in place.

[DesktopDave]

Actually, that "zero-position" adjustment method works perfectly.  It compensates for any mounting trouble with the panel and aligns the cables ideally.  Once they're locked in place, you can mess with the height of the panel casually.  I did note that the lower panel catches slightly on the spoiler while closing, but it's not significant enough to worry about.

The switching gear turns at twice the speed of the control gear, but only turns it with every other tooth.  So they're sync'ed from what I can see.  Why the different sizes then?  It's not for mechanical leverage (the worm & transmission gears take care of that), maybe it's just a packaging/space decision?

The roof stop position is smack dab perfect as well.  I can hear the click of the relay at precisely the correct spot.  I have a spare (of course) but couldn't lay my hands on it.  Looks like a standard Bosch two pole relay (5-terminal) though.  I'll bet that the slip clutch saves the gears long enough while the motor overloads to click that relay open.  It might be an over-voltage setup.  I'm told the windows work the same way.