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Two possibilities and two possible solutions.
DIAGNOSIS:
1) The hinges may look fine but become very slightly dried out. Because these hinges must be incredibly sensitive to work right the slightest resistance can cause the flap to become stuck when the roof moves forward, leading to the condition you describe.
2) If you hit the flap repeatedly with the sunroof you may have bent or warped it slightly, pushing the middle of the flap up. This would cause it to be high in the middle where the roof comes closest to contactinbg the flap, making the flap too high for the roof to clear.
SOLUTION:
1) spray some lubricant (silicone, wd-40, whatever) on the six springs/hinges of the flap. Two on the front where teh flap connects with the housing, and four in the sides where the arms connect with the body and the flap. Then work the flap up and down for about 30 seconds to a minute to get the lubricant worked into the grooves.
2) Put two small wood blocks under the outside corners of the flap (about 1.5" square). Next, place both hands on top of the middle of the flap and press down gently to try and flex it flatter. Make sure to use both hands to dissipate the force over a wider area (not that you actually could crease it or anything, but its always best to dissipate force in this kind of operation).
Good luck,
Rick
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