Further the the answer from bluedot -

The leaks between glass and frame seal drip closer to the center of the car than where the leak trays are located.

Our 960 is a wagon. We fought this battle for two years while searching for a used sunroof.

Tried the sealant method, and got a little relief. It is difficult, and a 2-person operation, to get the glass clean, lift up the edge of the rubber seal, squirt in some black marine sealant, get it neatly cleaned up, and then wait for rain.

We also got a large sheet of plastic and eight magnets to be able to cover the sunroof area if rainy weather was coming. Of no use while driving.

For that, we used 11" x 11" paper towels, rolled up to 1/2-inch tube and stuffed into the front corners of the moonroof opening. Have plenty of spares around, they fill fast in heavy rain. Can be done by one person - using lotsa care.

We left the sun shield open, too. Figured that it would be cheaper to replace that the headliner, which shows signs (sagging) of water damage.

Water ran down the inside of the "A" pillars, dampening the outside covers. water also wetted the trim piece that runs along atop the front and rear doors. We also got water running out of the dome light.


The used unit was 140 miles away, sworn to have never leaked. Takes 4 screws to install, once the trim bits of plastic covering the screwheads are removed. Removal and installation took under an hour, even with a number of re-adjustments.

For adjustment the Volvo Service Manual says:

The rear edge of the sunroof must be 0.5 mm above roof level.

In case of contour differences between the sunroof and the roof, the rear edge of the sunroof must never be below roof level.

The front edge of the sunroof must be 0.5 mm below roof level.

In case of contour differences between the sunroof and the roof, the front edge on the sungoof must never be above the roof level.


For a used one you can check junk yards and disassemblers, and the "Parts Cars" section of eBay Motors. I found mine on this brickboard, from a wrecked S90.

It all worked. No leaks any more. We celebrate in rain.

Good Luck,

Bob

:>)