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Don:
Here's something to check. Open the sunroof partially (opening back, not popping up), and find some sort of landmark in the track (something like a groove or screw that exists in the same place on both the left and right sides). What you're looking for is to see if the sunroof is opening evenly on both sides. If you line up the right side with a certain point, when you look at the left side is it exactly the same?
If there is a difference, your crank gear may have just skipped a tooth or two on one side only.
To fix this, you can remove the crank and gearbox (very easy). In the hole that's left, you will see two toothed cables. I believe the rearmost cable operates the left side, and the forward cable operates the right side. Use a small flat blade screwdriver to slightly move either cable until both sides of the sunroof are perfectly aligned with the landmark you have previously chosen.
Then, replace the crank and see how you did. NOTE: When you replace the crank, it's likely that the park position (where it clicks) will no longer be synchronized with the sunroof. The next step, therefore, is to get the sunroof perfectly closed, then remove the gearbox and crank again and, holding it in your hand, operate the crank to find the "click" point. Then, replace the gearbox and crank again. Once this is done, you should be all set.
Sometimes it takes a little trial and error to get the synchronization of crank and roof perfect. Be sure you open and close the roof both ways to check this.
I've made these adjustments to mine a few times. It's not hard.
Hope it goes well.
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Guid ('92 745 257k, '91 940 SE 278k,)
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