We ought to condense all these sunroof topics.
Have you read this sunroof thread yet?

 

The seal is not a perfect one and leaks can happen just from rain. Even going through a car wash, the high speed blowers at the end can force water through the seal. Any water that gets through to the headliner will create ugly stains. The drip tray has two functions. One, it prevents you having the sunshade closed and forgetting that the sunroof is open. Two, it drains water off to the side gutters towards the drains.

The only parts you need to repair this are two small washers as described and shown in this thread: https://www.ford-trucks.com/forums/3...s-loose-2.html

 

Great posts here and some creative thinking led me to an idea.
Rather than drop the headliner:
Take out one of the map lights just above the 2nd row seats. Look in the opening to see where the motor and gear is located (you can just barely see the location where the Allen wrench is supposed to be inserted, but you can't reach it from here). I found a picture of the sunroof motor for my Exp on Google, which confirmed where the Allen wrench fits in to turn the manual crank: see link: Google Image Result for http://cdn0.autopartsnetwork.com/images/catalog/brand/cardone/640/42729srm-bac.jpg

What I did then was pinpoint the location on headliner (towards center of headliner and about 8" in front of where the map light opening is located) that matched where the Allen wrench could be accessed if I poked hole through the headliner just below it. (I then punched a small slit in headliner with a metal letter opener that was handy and bingo!!). I then used an Allen wrench that was long enough to push the tiny slit I made in the headliner, and while shining a flashlight through the map light opening to see where to insert Allen wrench I managed to easily insert the Allen wrench and turn it just slightly. Then I turned the ignition on, hit the sunroof open/close switch and it worked perfectly.
Since this worked I didn't have to manually crank the Allen wrench to close it, but from all these posts that's how other manually cranked their sunroof close. If you're lucky enough to just barely turn the crank to "unstick" the motor, perhaps you'll save yourself a lot of money and a lot of time since you won't have to drop the sunroof.

Good luck!

 

The sunroof on my 2004 EB Expedition is stuck in the "UP" position. The motor tries to pull it down but can't. HELP!!!

 

Did you look to see if anything is obstructing movement?
Did you check the alignment of the glass to make sure it's still lined up with the roof opening?

 

Yes, that was my first thought because one side was trying to go down but not the other.

 

I had the exact same issue as OP. Reading through the posts, I thought Jeff M Texas' idea sounded like a winner. Jeff M's heat/ac configuration must be different from mine, however, as removing the 2nd row map lights would not make the motor visible. I have a 2001 EB Exped with the factory VHS video player (an antique now) just behind the moonroof opening. It has the rear air option; the 2nd row seat area has 3 heat vents in the ceiling. After lowering a portion of one side of the headliner I could see that the part where the Allen wrench needed to go looked like it was directly over the middle heat vent. I removed the vent (1/4 turn counter clockwise & it drops out) then cut a flap/door in the plenum ceiling w/an exacto knife dead center above the hole where the vent was -- and bingo! There it was! If I would have known, wouldn't had to have messed w/the headliner at all.

Cranked it closed (kept trying the switch periodically but wouldn't close electrically). It would open but would still not close. When I went to crank it closed all the way, there was a loud clanking sound when the glass was about 3" from the fully closed position. I have no idea what happened but the moonroof works once again like it should!

Again, I don't know if my vent configuration is typical due to the video player. The 2nd row side vents are forward in the ceiling, while the center one is back, about 6" forward of your face if you're sitting in the middle of the 2nd row.

Hope this is helpful to someone.

 

I had the "stuck in full open" sunroof/moon roof issue. My brother and I pulled the headliner down from the side (passenger door area) and used a flashlight to look across and locate the motor drive shaft. My brother used a nail to pierce the headliner until we hit the hole while I gave him corrections. Then I used a 5/32 allen wrench to engage the motor and start crnking the roof shut. Once it had moved an inch or so, the switch worked and it closed under power. I don't really know what the "correct sized" wrench is but 5/32 worked. I have read some posts that said it was a torx bit but I could not find one that fit it.

I think a good idea would be to cut a 3/4" hole at that spot and put in a nice looking plug. Then when it happens again things will be easier to see.

 

Do you mean from the factory or that each of us should do it now?

 

Well, the factory should have but that horse is out of the barn

I mean IF you have a problem, may as well cut a hole while you are there. It makes it easier to see where you are working and chances are you might need to manually crank it again. Why go through all the trouble twice. It might be wise to carry the allen wrench in your glove compartment.

My jaguar sedan has a little crank included for just such emergencies.

 

Might I suggest you make a DIY post with measurements as to where to make the hole. A picture or two would be a bonus. Such a post could help someone else in the future.

 

Good idea. I will do so when I get back from my trip to Texas.

 

Don't know if anyone is still monitoring this thread but I was wondering if the DVD player in a 2010 Expedition poses any problems in getting to the motor on the moon roof.


My wife's Expedition is stuck in the vent position. The motor sounds like its moving back and forth completely but the glass won't go down. I didn't know if the 2010 model had changed enough to make the instructions on previous posts here obsolete ...?


Thanks.