Hey everyone, I recentl bought a 1990 240, and the manual sunroof will open about an 1/8 of the way before sticking. What can I do to fix this?

Most likely what is happened is that the crank assembly was removed and not re-installed properly. Try this fix:

1) Close the sunroof all the way.
2) Remove the two screws that secure the crank gearbox and remove the gearbox.
3) Now with the crank gear box removed, continue to wind the crank as if you were closing the sunroof until the crank hits its limits
4) Re-install the crank gearbox

I find that the screws that secure the gearbox in place tend to rattle loose over and over. I used some loctite after I had similar issues and haven't had any problems since.

Many people do not think of this, but you should read the sunroof section in the 700/900 FAQ - your sunroof is similar if not exactly the same as 700/900 sunroofs.

This also applies to many other issues that may come up with your 240.

One thing that you can check easily is to remove the sunroof handle and gear train.

It has a system to stop when the sunroof is closed or fully open. It should take several turns to fully open, If yours does not when it is removed, perhaps the gear train is faulty.

When I converted my 745 to manual, it did not stop in the proper place - I had to close the roof, remove the gear train, and fiddle with it to get it to the proper spot to stop. It worked flawlessly after that.

I got my used gear train at the junk yard.

Ahh....the 240 sunroof.
Have you tried to "help" it
Open? While turning the crank
Use your other hand to give assistance and push the sun roof at the same time....this technique is also helpful while closing her too.
But, be ready to take her apart once it is open, because she may not want to close after getting her open. It is not rocket science, but it is time consuming. If having to remove her completely she lifts out with rails attached after ALL screws and winding wire/rod tracks are removed. Do not lose any screws and take pictures along the way. Good luck. I've taken mine out a few times for maintainance and fixing. Have a flashlight handy to look into the space between the roof and headliner. Might as well have a long wire, like hanger wire but a little longer, ready to clean out the water channels while you have her apart. One canal in each corner (flashlight is helpful here). The front two drain out near front door hindges and the rear two go through the trunk area and drain behind the rear wheels. And again good luck. Have at least an afternoon free and a garage available if it might rain. Don't ask me how I know.