I replaced my main and sunroof headliner Labor Day weekend. I removed the sunroof headliner by dropping the water pan and sliding it out the back. After replacing the fabric I slid it back the same way (I thought) as I took it out. Then I installed the main headliner and put all the mouldings, mirror, visors, dome lights, etc back. I thought all was well until I tried sliding the sunroof headliner forward from the pan area and found it would slide only to a certain point and then would stop. It would not slide into the sunroof opening. I looked with a flashlight and saw the passenger's side front tab (one of 4 spot welded to the sunroof headliner) was out of the slot and was riding on top of the track. The raised metal tab was hitting the back part of the control mechanism (one of two arms that raises and lowers the metal sunroof) preventing it from sliding into the opening area. Do I have to remove the main headliner again, lower the water pan, slide the sunroof headliner back out and put it in the correct way OR can I remove the control mechanism and then maybe slide the stuck headliner into the sunroof area where I can try to get the tab back into the slot where it belongs OR do you have some other idea how I can get that one tab back into its slot when it is hard to reach?
Thanks ahead of time to all headliner people.
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Keith's 1990 740GL wagon 215,000 miles B230F 8 valve non-turbo Regina Rex AW70L

The proper way is to remove the sunroof, then the sunroof mechanism, and slide the sunroof headliner panel out. This is much easier than dropping the headliner. I have done four 700 series headliners, and they aren't much fun.

If I haven't already sent you a file on removing the sunroof, just respond to this post and ask for the sunroof file.
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john

John,
I'd like to see your sunroof file please. Thanks.
Keith
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Keith's 1990 740GL wagon 215,000 miles B230F 8 valve non-turbo Regina Rex AW70L

Agreed. The proper way to do the sunroof is to pull the outer panel from the top of the car (outside), then pull the mechanism out the hole from the top. Dropping the headliner is a total pita, and dropping the headliner to remove the entire sunroof housing is a nightmare I can only begin to imagine.

Just unclip the retaining springs, remove the sitting screws on the sides, and then remove the front screws to fully release the outer panel.

good luck,
rt

I have sent the file. I hope that juno will accept it. If not, you will need to send me another email address which will. I have stopped sending Volvo maintenance files to anyone with hotmail accounts. The hotmail accounts won't accept the large files. You can't expect too much for free.
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john

John, do me a favor and send me the same file so I can correlate comments in the FAQ.