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Dear macs70GLT,
Hope you're well. I infer this 940 is a sedan. Because it has a sunroof, I infer there have been some leaks. That could have caused the headliner backing board - made of fiber board similar to "Masonite" - to deteriorate.
The headliner backing board is not affixed to the metal with glue. Rather, the backing board is held in place by trim pieces along the edge, around the sunroof, and by a few fasteners at points in the center.
A nephew, who has a '90 760, had a failed headliner. He re-built the backing board with an epoxy resin and fiberglass fabric. The epoxy, applied as a "liquid" bonded with the fiberboard. The fiberglass fabric, bedded into epoxy, reinforced the weak sections of fiberboard and made them as strong, or even stronger, than new. He sanded the down-ward facing side of the repaired backing board. Once it was perfectly smooth, he applied new headliner fabric to the backing board, and re-installed.
There is no good alternative to removing the failed backing board, and replacing it or restoring it.
This is a two-person job: the backing board is large and there's little maneuvering room in a sedan, in terms of removal and replacement. When you replace the headliner, be sure to wear gloves, so as not to smudge it.
Hope this helps.
Yours faithfully,
Spook
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