Opensky roof problems

[monkeyfinger]

Anyone else had problems with the opensky roof? Wife's car roof no longer works. When button is pushed the roof will move maybe an inch and then make a rapid clicking noise (like clutch slipping or gear teeth jumping). Looking at the motor, I can see the shaft turning when this happens but no movement of the roof. I'd appreciate any advice, but it looks like motor and/or gearbox will need replacing. Has anyone had to do this and if so is it straightforward or a definite dealer job? With the manual override crank handle, I was still able to fully close the roof. - Thanks

[Skipton01]

Your problem is to do with the splines on the gears, as you correctly thought.

The gears themselves are not available separately, you will have to buy the full motor assembly unfortunately.

I have seen these advertised on Ebay, a few weeks ago now. Failing that, either a breaker or dealer will be the only other options (or you can use www.vagparts.com and benefit from a 10% discount when you join the club membership scheme - shameless plug!!!).

From memory, the motors are about the £100 mark, but don't quote me on that.

As I am at work at the moment, I cannot give you the correct part number, but if you've not got it in the meantime, I'll post it this evening.

[monkeyfinger]

Thanks for your comprehensive reply - I already checked motor/gearbox price with Southampton Audi, and got £265 incl vat! Food for thought...

I haven't spotted one on Ebay, but will hopefully track one down - any information on replacement would be appreciated. I have had a bit of a look and there seems to be a number of Torx screws holding it in place.

I would definately have a go myself, as price of motor plus a couple of Audi hours will push £500...

[Paddys]

I had similar probelms myself when there was a grating noise when I tried to close my opensky and it stuck....

the Steeler did one of those rubbing his chin whilst breathing in kind of things but in the end they managed to do it for the cost of the basic inspection - mind you that does work out as the most expensive car wash ever....

They claimed that it it gets stuck again then the only solution is a replacement opensky system at 2100+VAT + Fitting.... not a cheap one. VAG are a lot less but I wouldn't fancy fitting it myself!

I may try and remove the gearing and try to get someone at work to make up replacements - If i do and have any sucsess I'll pass on the details.

[monkeyfinger]

I've been thinking the same regarding remanufacturing metal replacement parts - I guess the gears are nylon or similar, and the strain of breaking the seal everytime the roof opens has eventually caused a failure.

[spike]

Hi
A club member in Japan had similar problems with his sunroof and I suggested he contact Arvin Meritor, the original manufacturer, regarding the supply of individual service parts (pretty unlikely I know) See attached links to the original thread and Arvin Open Sky roof
http://www.arvinmeritor.com/media/Low_Resolution/car_and_light_truck_products/roof_systems/CPRS018L.jpg
http://www.a2oc.net/forum/showthread.php?t=3301&highlight=sunroof

Cheers Spike

[hollyrescue]

I suppose I am tempting fate by saying this but....... My open sky used to stick and frightened the living **** out of me listening to the tortured noises it made attempting to open itself, so much so that I was scared to open it in case it wouldn't close. It went back under warranty a couple of times and I was told it needed adjusting etc. etc., it would be returned working well and looking clean. I decided that probably that's all it needed. Since then I have cleaned it very regularly all around the edges, and every bit of black rubber associated with it, also all the surfaces that mate with the black rubber. You'll need a tooth brush and a clean absorbent cloth (towel is good), remember to clean the brush and towel before returning them to the bathroom before 'er indoors finds out. At this point I would spray all the rubber with silicon grease from Mr VW, and everything worked smoothly with only the slightest clunk when it picked up the rear glass. But..... last week whilst going to get some more silicone grease from Mr Halford I discovered 3in1 PTFE professional (that's me, professional!) spray at £5.99, as against £3.99 for the silicone. I did the cleaning routine and used the magic spray. It worked so well that I did all the caravan window seals with it, and they don't stick any more. I know that it is alleged that silicone furniture spray also works, but not as well as this one. I shall now go out and buy a million 3in1 shares and clean up!
Seriously though folks I hold no brief for any product, but very regular meticulous cleaning and a suitable spray has taken a lot of the fear out of using open sky. I'll now go and try mine because the law according to Dr Sodt says......

[tdiman]

Please be very carefull with that silicon spray, probably paints number one enemy according to ZYMOL spray onto a cloth away from the car and wipe on the rubbery bits!

[hollyrescue]

tdiman, thanks for the tip, I do it carefully using the extension tube, and avoid everything except rubber bits, but I was not aware of the possibility of paint damage. Is PTFE a problem? Is it a silicone? I was not so careful on the caravan but can see no problem at the moment.
I'll give it regular clean and spray treatment and report back after a few weeks. I'll either have a perfectly working open sky, no paint, or both.
I suppose if open skys are a constant problem which is expensive to cure, then taking the fuse out and leaving it closed offers many advantages over non open sky. No doubt as the A2s pass into veteran and vintage classics it may be the only answer. Or the A2 club could get so big that it could have parts manufactured as do many other marques.

[Skipton01]

As promised, if you need it, here is the appropriate part number for the roof motor:

8Z0 959 591

Best of luck with whatever solution you go for.

[monkeyfinger]

I just wish my problem was as simple as sticky rubber....had another look at the motor tonight and it definately looks like the gears are slipping. Also looks a right sob to replace.

[alexm]

I can endorse Hollyrescues recommendation of Silicone spray. My open sky was getting a wee bit stiff and making a few clunks especially when it 'picked up' the rear glass panel. However a thorough spraying with the silicone has (touch wood) solved the problems.

It might not help you now Monkeyfinger but I think regular spraying will help reduce strain on the motor and thus deal with longevity issues.

As an aside a colleague at work had problems with his opensky. The A2 chasis had some how warped. Audi had to fly in a jig from Germany to straighten it!! :eek: Lucky for him the car was under warranty.

[Paddys]

What we need to do (if we want to get them manufactured (and I have an engineer here who can do it)) is try to obtain this from a wreck so we have an "unblemished" system - or I just bite the bullet and pay for one and sell the spares to make the money back ? What are the gears made of at the moment ?

[monkeyfinger]

What I need is some info on how to get the motor gearbox assembly off the car. I had a look last night, and removed 3 torx screws around the assembly, which hold it to the roof, but it is still attached to the cable tubes (?) which I guess push/pull the roof. Is there any workshop manual style info. for this? If I can get it apart then (looks like it splits), I could even produce drawings of the internal parts that may be worn.

Any info. appreciated

[spike]

Hi
The manual (available on disc from Skipton) is not too helpful. All it says is -
Remove the interior light
Detatch connector
Unscrew the bolts (item 3) and remove the motor

Installing

The motor may be installed in any desired position of sunroof versus motor
Insert motor into the sunroof and tighten bolts to 4Nm
Connect the motor
Close the roof completely
With the sunroof closed, press the switch to the closed position and hold the switch in this position for approx 10 seconds
This serves to initialise the motor in the basic setting.

Wonder if the motor has some sort of torque limiting clutch mechanism which could be the problem. Also, if there is a Bosch part number on the motor you may be able to buy it cheaper from a Bosch dealer.

Cheers Spike

[monkeyfinger]

That's good info - I took the 3 bolts out and the motor seemed fixed, but obviously I need to apply a little more force.

I'm very interested to see what's inside - had a look on ebay, and there are a number of sunroof motors for other vehicles that look very similar, and may contain gears that I could use (other vw's, audis, bmw's etc). The A2 ones seem very rare, although I may get lucky,

Thanks for taking the time to get this information.

[monkeyfinger]

Finally got motor off - actually very easy because I had missed a 4th screw which is recessed through the centre of the housing.

I've attached a couple of pictures of the motor assembly which splits into 2 main bits - the motor and gears, and electronic control. There is a sensor (arrowed) which I presume will pickup when the motor is not turning. I'm hoping the cables left in the car are ok, as the manual key override was still working to allow the roof to close. There doesn't appear to be any wear in the gears whatsoever, so as soon as I get a chance I will put 12v on the motor and see what happens.

Meanwhile if anyone knows of a motor for sale...

[spike]

Hi, good to see you have got the motor off. I had another look at the manual in the hope of finding a test procedure for the motor or troubleshooting info for the roof mechanism but could find nothing extra.

Cheers Spike

[monkeyfinger]

Have established that the motor/gearbox is not the problem.

The drive pinion seems to slip intermittently where it engages with the cables that push/pull the glass panels. These seem to be well gunked up with greasy fluff when I look at the engagement point.

Next course of action will be a thorough clean of the rubbers and mechanism - not sure how to approach replacement of the cable assembly at the moment if that becomes necessary...

I think this emphasises the need to keep everything sliding smoothly to reduce the strain on the drive gear.

Will keep you posted

[monkeyfinger]

Had Southampton Audi have a look at my failed roof yesterday - they have condemmed the whole mechanism :(

Although they lubricated it, the roof is now skewing as it slides forward and back. They are pricing up the bits and I should get a quote tomorrow. I'm pretty sure this will be a four figure sum, so I now have to decide a course of action. Obviously we could treat the roof as just fixed glass and drive as we have been and be fairly happy (climate control helps), but we intend to keep the car for a couple more years yet. The problem would then come when we want to sell the car (best sold privately rather than part exchange I think).

I think we will have to bite the bullet and get the work done in order to enjoy the car and ensure long term value. I will definately get the old mechanism back and have a good poke around with it when the work is completed.

If buying another A2 I would have to think verrrry carefully about the opensky option, as it cannot be worked upon, just thrown away and replaced if it fails. Not a good piece of engineering, but I guess more for design and aesthetics.

[Xiter]

When I replaced my old A2 (with open sky) I went for one without this feature.

[Paddys]

I've basically accepted that if I open my roof there is a large enough chance that it will fail and cost me $$$$$ that I now don't use it. I think that as a feature it adds a lot of value in just the extra light and feeling of space and I certainly didn't pay any extra because of it...

[Erling]

Hi all.

Found a spare OpenSky on eBay for someone to keep for a rainy day or to replace a washboard solid roof? Anyone interested?

Complete roof assy with fixed/moving glass, frame and motor with breaker.

Description: Audi A2 Panoramaschiebedach mit Motor, Antenne
Item: 150009789020
Location: Germany

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=150009789020&ssPageName=ADME:B:EF:UK:11

Ciao,

Erling

[Niall]

Hi..I have an openroof with the same problem...opens about an inch and then slicks/grates...could you let me know what the solution in your case was and any suggestions as to where to get it fixed?Many thanks Niall

[monkeyfinger]

Niall - I'm afraid this sounds pretty much like my problem. Unless you consider approx £1500 replacement job from Audi as worthwhile expenditure for a working sunroof, I suggest you do as I have done, which is accept the failure and put up with a non-functioning roof. I think the main benefit is the additional light it provides any way, as there is so much wind noise when it's open.

Repair is possible with the appropriate parts if you can get them, but it's the labour cost that makes this a killer - I couldn't find any specialists prepared to touch it. Replacement requires a special alignment jig, which pretty much makes it an Audi only job.

[A2Look]

All this makes me feel glad I dont have it.

[alexwharton]

Do local body shops not have this JIG then?

[Skipton01]

Do local body shops not have this JIG then?
No - most dealers only have one per region, which gets passed around as and when it's needed.

Cheers,

Mike

[Adrenaline]

My opensky roof was making clicking noises but today since it was nice weather thought id open it, but it wouldnt fully close...i was like wtf i had heard of the costly repairs...took me two hours of constand opening and closing to finally close it...it made really loud crunching and clicking noises
and the roof was sliding out of place....once i got it shut...phew i was thinking of removing the fuse so that it never gets touched...after hearing about the replacement cost...climate control would do me fine

was going to remove fuse but its also for the horn :mad:

[spike]

Hi Adrenaline

In January, Mark Brigg posted the attached mail relating to an Open Sky roof mod. It may be worth checking if this is available yet (sounds expensive to fit though)

Cheers Spike


"There is soon to be available a roof repair kit developed by Arvin Meritor the OEM supplier. The glass has to be removed and a small pressing put into postion. It solves the problem of the roof twisting.

Which specialist roof repairer did the vendor use in Hampshire? Could this repair kit have worked, do you think?"

[Skipton01]

Just opened my roof today for the first time in about 8 months and even though I take care of it and the seals, I had to give the second panel a little help with a gentle shove to get it open.

The OpenSky system really does seem to be a touch fragile in its design and operation.

Cheers,

Mike

[SnubNose]

I love the Open Sky - I read through this post again with a little concern of all the potential problems above my head.........but you just have to look up and around and enjoy all the extra light and air that it provides.

Not to mention the way that it makes the car look! If I take her to work and park outside the office, when I look out from the first floor, the gleaming tinted glass that runs from the bonnet to the boot looks fantastic and makes her stand out from the crowd.

Anyhoo, all that said, yesterday I gave the roof guides, seals, rubbers and anything else that I felt may hinder the smooth operation of this wonderful optional extra, a damn good clean and lube using all the hints and suggestions in this post.

Opens and closes like a dream - just buffed the acre or so of glass and the jobs a goodun!!

Thanks to everyone for your Open Sky (did I mention that I love it??) hints, tips and suggestions! Long may she provide trouble free sunshine.

ps. I did think, while reading, regardless of the problems that if anyone of us went to buy another A2, and ended up looking at two at a similar price with the same spec except one had the Open Sky - we would ALL go for the Glass Roof, yeah baby, you know you would.

[mjs4x4]

Yes - tend to agree with Snubnose - even if it suffers premature failure and neveropens again it is a nice extra!!

In fact it seems a lot of car makers are going over to fixed glass roofs - so, hey, even with a busted Open Sky - you'll be bang up to date!!

[crawfster2]

Yes, big prob on Friday evening. Went to shut sunroof. KER-TWANG. Roof would not close. Very windy drive home, fortunately didn't rain. Took to Perth Audi. Apparently, cable from motors to roof has snapped, entailing £1,000 of work. Currently searching cheaper quotes. Extended warranty company are weasling out of it, despite telling me it is covered. Combined with inability tomount roof bars, there's on ething I wish I had known in 2002.... don't buy an Open Sky..... Crawfster

[monkeyfinger]

Glad I'm not the only one in this position, but sympathise with you anyway!

Instead of removing the fuse, I would suggest that you drop out the panel holding the roof switch (and interior light) - it's very easy to do by removing the lamp cover and then pushing the two small metal clips that you will see on the leading edge.Then you can detach the operating cable from the switch to prevent unwanted activation.

Hope this helps

[crb1011]

crawfster2 are you with warranty direct for your extended warranty by chance

[Mark Brigg]

Please see my comments to Heather's thread re her roof problems. There is a fix available through Audi from ther roof manufacturer.

[Mark Brigg]

Spike I just posted some details and a presentation (sorry in German- time to get your Eng/Ger dictionaries out!).

The repair is not simple for the likes of me, but should be a lot less that some of the stupid money quoted for repairs such as new roofs etc.

[spike]

Hi Mark

Thanks for update. I see the guide lists the Audi p/n for the new bit so it could be done at home if you have the skills and nerve. Looks like more of a preventative measure than a fix for a broken roof though.

Wonder if any members of the German A2oc have tried it yet.

Cheers Spike

[Mark Brigg]

Sorry for the late reply, Spike.
No it is a fix for the Open Sky roof for when the opening mechanism fails.

Has anybody who had problems with their roofs tried this yet (Monkey Finger, Heather?)? and if so how much? Please don't keep us all in suspense.

[Heather]

My A2 is due in to Derby Audi on Thursday for its 2nd longlife service and they are keeping it in for a couple of days to look at the roof.
Am keen to hear what they say has happened, after hearing about everyone elses problems on here.
I've had my A2 for four years next month, so am now out of warranty. Guess i'll have to start fluttering my eyelashes at those nice technicians!!!

Although the roof is closed, its not fitting flush and can hear lots of wind noise at speed. Luckily also not letting in any wet.

I should probably start another thread for this, but my indicators are giving me grief as well this week. Fast/slow/intermittant flashing and sometimes nothing at all!

Will report back re the roof,
Cheers, Heather

[spike]

Hi Heather
When you go to Derby Audi it may be worth taking a copy of the roof repair procedure Mark Briggs posted on the previous page (It's in German unfortunately but the pics clearly show whats involved in the 'fix') Suggest there must be a design fault with the roof and ask if they will submit a policy claim to Audi on your behalf. If the eyelashes don't work, a few tears may do the trick.
The flasher relay is also a known problem but fairly easy to fix - see link for more details
http://www.a2oc.net/forum/showthread.php?t=4895&highlight=flasher+relay

Cheers Spike

[monkeyfinger]

Following on from Mark's earlier post (and many thanks to him for the effort he put in to getting this repair kit made available), I have taken the decision not to progress a repair at this time.

Bearing in mind the age of our A2, and it's current value, I cannot justify the massive labour charge that I know there would be from Audi to carry this out. At least it would save the cost of a new roof unit, but the old one still needs to come off, be repaired, and then go back on (with the special jig).

Lets say 2 hrs to remove, 2hrs to repair, and 2 hrs to replace - plus bits and pieces - must be approx £600 (any views?). Now, how much is my 2001 A2 petrol worth - maybe £4k? I think that's too big a percentage to justify...

As we intend to keep the A2 for some years yet, I'm sure a sliding or non-sliding glass roof will have little effect on it's final value.

Maybe some comments will be forthcoming!

[Heather]

Thanks a million Spike for the info. I've printed off the open sky diagrams ... and am about to dash up to me Dad's (who can speak German)! for a quick translation.
As for the indicators, I wish I had time to ask one of the engineers at work to have a look (they are rather good at fixing aircraft) but will be without the A2 from tomorrow onwards so wont get the chance.
Desperate to get these done now as was on the M1 this morning with NO indicators working - Not good!!

[Heather]

Update on the open sky -
Took the A2 in last Wednesday for second service, indicator relay repair and to have a look at rather poorly open sky.
As ive been in the sky all week (at work) at stupid hours and uncontactable I didnt get to speak with Derby Audi until Saturday morning.
I can pick the A2 up tomorrow once the indicators are done, but will have to speak to a technician about the roof.
As yet, I dont know what has caused the problem, will find out tomorrow, but the receptionist said they need to do a modification which will cost £277 ... which may or may not work. If it doesnt, then i'll need a new roof!
I explained that this seems to be a common problem and she said that Audi may do it as a good will gesture.
Im really not prepared to pay £277 if its not going to work!

Will see what they say tomorrow

[Smick]

I'd say though that if it does, £277 is quite reasonable. It will be especially nice to have everything in order coming into the summer months!

[trendylife]

Update on the open sky -
Took the A2 in last Wednesday for second service, indicator relay repair and to have a look at rather poorly open sky.
As ive been in the sky all week (at work) at stupid hours and uncontactable I didnt get to speak with Derby Audi until Saturday morning.
I can pick the A2 up tomorrow once the indicators are done, but will have to speak to a technician about the roof.
As yet, I dont know what has caused the problem, will find out tomorrow, but the receptionist said they need to do a modification which will cost £277 ... which may or may not work. If it doesnt, then i'll need a new roof!
I explained that this seems to be a common problem and she said that Audi may do it as a good will gesture.
Im really not prepared to pay £277 if its not going to work!

Will see what they say tomorrow

Did you manage to get the problem with your open sky resolved? I've got the same problem with mine, does anyone know what the £277 repair was?

Thanks.

[Heather]

Slight glitch with the proceedings ... they will start work on it now on Monday so will let you know-
What they say the prob is
What they did
AND if it worked!!!! ... fingers crossed.

[spw]

Hi Heather,

Was the Open-sky fix successful ?

sw

[Heather]

Today i am very happy.
Derby Audi have had my A2 for a week and a half to repair the roof. After talking to customer services several times they agreed to pay for the £277 modification which may/may not fix the roof.
When they took the roof to bits they found that a new roof was necessary so the manufacturer has replaced it- parts and labour free of charge!
This is a great result as i thought i would have to stand half of the cost. I asked the cost of a new roof and was quoted around £2000
I enquired as to what would happen if it breaks again and they explained that as the manufacturer has stood all of the cost that it is not covered by any sort of warranty. But as it is a known fault with my car then Audi would obviously look in to it again.
I have had a courtesy 2ltr A4 to drive whilst mine has been in and although a nice car, not half as much fun to drive as the A2 ... im pleased to have it back.
Well done Audi for sorting this out!
If you have an A2 with a dodgy roof dont just refuse to use it. If they have replaced mine ...

[Skipton01]

Today i am very happy.
Derby Audi have had my A2 for a week and a half to repair the roof. After talking to customer services several times they agreed to pay for the £277 modification which may/may not fix the roof.
When they took the roof to bits they found that a new roof was necessary so the manufacturer has replaced it- parts and labour free of charge!
This is a great result as i thought i would have to stand half of the cost. I asked the cost of a new roof and was quoted around £2000
I enquired as to what would happen if it breaks again and they explained that as the manufacturer has stood all of the cost that it is not covered by any sort of warranty. But as it is a known fault with my car then Audi would obviously look in to it again.
I have had a courtesy 2ltr A4 to drive whilst mine has been in and although a nice car, not half as much fun to drive as the A2 ... im pleased to have it back.
Well done Audi for sorting this out!
If you have an A2 with a dodgy roof dont just refuse to use it. If they have replaced mine ...
Great news indeed Heather!

It just shows that a little perseverance (and a bit of eyelash fluttering!) can win the day.

Here's hoping that you get many more years out of it - oh, and KEEP IT LUBRICATED!!!

Cheers,

Mike

[Heather]

No fluttering required this time Skipton!!!
Just hope the other drivers are as lucky ... and whats the best lubrication to use? ... dont want to damage me seals!!!

[Skipton01]

No fluttering required this time Skipton!!!
Just hope the other drivers are as lucky ... and whats the best lubrication to use? ... dont want to damage me seals!!!
A lot of folks swear by spray lubricant, but I prefer the silicone lubricant intended for underground pipe seals - you'll struggle to find a harsher setting than that!

I get the stuff from B&Q, it comes in a little bottle with a nozzle and is a white, paste/liquid.

The thing that most people don't do when lubing up their seals, is to clean off the old gunk accumulated there - if you don't do this, then you'll just be creating a grinding paste that'll kill your rubber in no time at all.

It can be a little fiddly, and the rear section is nigh on impossible unless you take out the blind and do it from inside, but persevere and it'll be worth it in the end.

Once you've cleaned up the old cr*p that's accumulated, run a thin bead of the lubricant along all the rubber sections (there's an inner and outer seal), then work this in with your finger.

Do this all around (and on the glass panels themselves) and you'll have a super-slick, happy OpenSky!!

Cheers,

Mike

[monkeyfinger]

Good to hear someone has had success with their roof - well done!

I doubt I would get far talking to Audi due to the age of my A2 (2001) - it would still be interesting to find out if anyone gets the mod repair done rather than a full replacement.

[Heather]

Will have a trip to B&Q!

The fact is that everyone should get this open sky thing sorted ... its a manufacturing defect that seems to affect everyone that has an open sky. I dont see that the age of the car has a bearing. Mine's 4 years old (03) If youv'e shelled out the extra money for this feature and it doesn't work then the manufacturer should accept responsibility?

They couldnt do the mod as the mechanism which pulls the roof shut had snapped (glide rail?), sorry not very technical this end!

[spw]

Heather, thats excellent news.

Mine's started making a few groaning noises from above the windscreen :mad:

[Skipton01]

Heather, thats excellent news.

Mine's started making a few groaning noises from above the windscreen :mad:
Ahhh, the noises and creaks from above the windscreen were driving me mad at the back end of summer last year.

I took Tank in, under warranty, and there was a technical bulletin that concerned this exact issue. 3 days later, all was well. I don't know what the solution was, but no parts were replaced.

Cheers,

Mike

[spw]

Thanks Skipton,

Thats good to know. The cars due a service in a few weeks so i'll mention it.
I was torn between main stealer of independent Audi specalist and there wasn't much in it price wise. This might tip it in the favour of the stealer.

[spw]

Hi Skipton,

Do you have any more details of the technical bulletin for the noisy opensky?
My cars just back from the stealers and there denying any knowlege of any such bulletin and there diagnostic was there was nothing at fault - however to fix it was a new mechanism at £2,000.

Less than impressed !! also annoyed that they said they'ed checked the brake lights and found on the way home ones not working.

sw

[Skipton01]

Hi Skipton,

Do you have any more details of the technical bulletin for the noisy opensky?
My cars just back from the stealers and there denying any knowlege of any such bulletin and there diagnostic was there was nothing at fault - however to fix it was a new mechanism at £2,000.

Less than impressed !! also annoyed that they said they'ed checked the brake lights and found on the way home ones not working.

sw
The technical bulletins are never shown to customers (or me!), but I did see the print-outs attached to my job-sheet and it concerned the spacing between panels and the sub-frame, which if too tight can cause creaking and sticking.

Cheers,

Mike

[spike]

Hi spw
I assume your problem is when the roof is closed so i'm not sure why they are suggesting a replacement mechanism.
Not sure if this is what you meant but in one of the earlier mails on this thread, Mark Briggs posted a repair bulletin for a reinforcing bracket which I think prevents the panels moving out of square and sticking - see link
http://www.a2oc.net/forum/attachment.php?attachmentid=794&d=1176793318

Cheers Spike

[Mark Brigg]

I think that it is about time that Audi were tackled about this problem. When Monkeyfinger first posted this problem I thought it outrageous that he was being quoted twice the amount that the roof cost as an option in the first place. When I saw that there were so many other roofs affected I tracked down the manufacturer who was genuinely very helpful. They clearly want their products working, have identified what goes wrong and have produced a cure. What seems in my eyes to be missing now is at the interface between Audi and its customers, the dealers.

What is not clear is what action Audi have taked to anounce the repair kit, what technical support has been provided to its dealer network. Reading the posts here it seems patchy. Of course dealers are agents of Audi, not Audi itself and so we see often a difference in quality of service and a difference in attitude. It may well be that many of them don't fancy the repair for fear of not getting it right or causing more damage. Really it is down to Audi to get a consistant approach so that these roofs are working. Ultimately it is Audis responsibility. I think even for older cars, there has been a long standing tradition within the motor trade about subsidised repairs for out of warranty work. Audi are a succesfull company.

It's a great result for Heather and I'm delighted for her. Pity its raining so much!

So perhaps a class action? All members here with roof problems write en masss to Audi. Ecoangel is trying the same method for the anti roll bar. The OpenSky should be added.

[manhattan$]

Good idea.

Even if a few people write to some of the magazines like Autoexpress, Audi Driver, Whatcar, etc.

Maybe they could get Audi into action to repair these under a special recall warranty?

[monkeyfinger]

I guess like most of these things, we must be careful not to get a distorted view of issues - most people on this forum are raising problems or issues, and we may find that 99.9% of Openskys work perfectly 99.9% of the time...(not that I believe it!)

I do find the small problems generated by my A2 to be frustrating - I now have the non-opening fuel flap to add to the list (have to hold down door open button whilst pressing the flap release). I'm sure that had the A2 continued, there would have been a mid-life update that would see more reliable electronics etc. introduced.

But we still love them :-)

[richard-]

I guess like most of these things, we must be careful not to get a distorted view of issues - most people on this forum are raising problems or issues, and we may find that 99.9% of Openskys work perfectly 99.9% of the time...(not that I believe it!)

I do find the small problems generated by my A2 to be frustrating - I now have the non-opening fuel flap to add to the list (have to hold down door open button whilst pressing the flap release). I'm sure that had the A2 continued, there would have been a mid-life update that would see more reliable electronics etc. introduced.

But we still love them :-)

ooo you live right near me, i've never seen an a2 in fareham/gosport areas on my travel's and i'm around nearly every day so I will look out for you

[Mark Brigg]

I don't think that writing to all the motoring magazines would be productive. We all like our A2's and are commited owners and as our vehicles get older (and in the future) parts will be harder to obtain. Later we will need the goodwill of Audi to keep them on the road. Very simply we should make direct contact to Audi UK and ask them for their help. State that we have X number of members with faulty OpenSky sunroofs that need fixing. We are aware that there is a solution from the manufacturer and can we have a special deal as we are an owners club. The nicer but more direct that we are I'm sure will get a response.

The A2 is a very interesting car and in the future Audi will be proud to have produced it, and the fledgling classic status will be of interest to them.
Simply giving the manufacturer a kick will not help us.

By the way my roof works perfectly, but its raining.

[manhattan$]

My experience with Audi was a kick in the teeth courtesy of them.

They are not exactly top of the customer service dealer charts in my books.

'goodwill' is a dealer swear word! :eek:

[spw]

Hi spw
I assume your problem is when the roof is closed so i'm not sure why they are suggesting a replacement mechanism.
Not sure if this is what you meant but in one of the earlier mails on this thread, Mark Briggs posted a repair bulletin for a reinforcing bracket which I think prevents the panels moving out of square and sticking - see link
http://www.a2oc.net/forum/attachment.php?attachmentid=794&d=1176793318

Cheers Spike

My problem is the mechanism is very noisy when opening and closing the roof.
It seems to be coming from the mechanism situated under switch in the roof between the windscreen and roof opening. The noise sounds more like a grinding from the mecanism and seems to have been getting louder.

The movement itself seems fine. I try to keep it lubricated and it only ocassionaly sticks breifly when its not been used in a few weeks.

sw

[monkeyfinger]

Be very careful here - my roof gears started slipping (and making a grinding noise) just before the whole lot packed up, with the roof panel 'skewing' in it's tracks.

It may be worth you taking out the roof switch panel (it just pops out), and feeling the motor as it operates. This may indicate if it's the gears slipping (you should also be able to see the end of the motor drive shaft rotating)

I'm happy to write politely to Audi regarding the roof - I guess anything is worth a try.

[ßeta]

My Open Sky just went yesterday.. Tried to close heard the gear grating sound.. Got it home and managed to get the roof closed eventually. Just come back from Reading Audi the cars booked in a week today. Let me see what they have to say next week. The car is only 4 month out of warranty with 13000 mile on the clock. Roof hardly been used.

[Heather]

I had a good chat with Trendylife a couple of weeks ago re the open sky. He has exactly the same problem as mine had.
I understand that Audi customer service has been less than helpful so far. In the last fortnight maybe there has been some developments? certainly hope so. Surely i cant be the only lucky one who has had the whole thing sorted with relatively little hassle?

I think it would be a very good idea for all of the A2's with the problem roofs be listed, like with the ARB issue. The open sky has a design fault which should be addressed and put right by the manufacturer.

No rain in Derbyshire for the last two weeks and the roof's been open every day - Brilliant!!

The original open sky clunked from new, the replacement is smooth as a baby's ...

[jimsa2]

Help! I'm also one of the unlucky one's with a roof problem.....

Yesterday I was driving home from work with the roof open, arrived home, went to close it.......clunk, right side was closed while left side was an inch open.
Tried to manually close it (as it says in the manual) but no go. Drove to my local garage who said I was best to take it to Audi.
Got to Audi, explained my problem and they thankfully managed to close it for me (after a few attempts), feeeewww!!

So the question is: What do I do now??
I know this is an old thread, so wondered if anyone has any updates on getting the Opensky roof fixed on the cheap, as Audi said yesterday this can be costly :(

Regards,
Jim

[mjs4x4]

Leave it shut and just enjoy the light!

They are damned noisy when they are open anyway!


Mike

[spike]

Hi Jim
In an earlier post (#37) Mark Brigg listed an Audi repair procedure which adds a stiffening bracked to the internal mechanism to prevent the roof 'crabbing' while being opened or closed. As its a known problem there is a slim chance Audi may contribute to the repair as a goodwill gesture if the roof does not respond to a good dose of silicone or ptfe lube.

Cheers Spike

[jimsa2]

Thanks for that Spike, will look in to this when I get some time.
I will be surprised if Audi help with the cost due to the A2's age now, but I can but try :D

Cheers,
Jim

[monkeyfinger]

My roof has been left firmly closed for nearly 2 years now...

As mentioned, Mark did stirling work in getting a repair option on the table, however, this still entails the full removal of the roof, which you will probably find will only be attempted by Audi (special jig needed etc.)

In my opinion, and for the marginal benefit that Opensky gives, it was not a cost effective solution. I think the main benefit is the look of the car and the additional light it gives to the interior.

I'm afraid that lubrication is unlikely to solve the problem, as I have tried alll manner of options on this.

[fbi]

I have crawled across the 8 pages of this thread, but I think no one has (had) the same problem as I have...
A few days ago, I closed my open sky and heard a 'crack' sound when the roof was ending to close, just if some 'stop' had broken. Now my roof still opens and closes, BUT when I press the button, I hear the motor running for 1-2 seconds before the roof starts to move (open or close). Moreover, the roof doesn't fully open (the second panel lifts and moves, but not fully backwards up to it used to stop). The roof closes, but the two 'slots' don't engage as far as before. Sorry for my poor explanations, English isn't my mother langage...

Do these symptoms speak to somebody ?
Where do I start dismantling to have a look at the motor/mechanism ?
Thanks in advance,

Fabrice

[ijedgar]

My wifes A2 has opensky,she has had the car for a year & 3 months of that time it has been with the dealer trying to fix the recurring problems associated with the roof.
Luckily she bought from a dealer & all the work has been warranted,if it had not been we would probably be bankrupt by now.
The roof would be fixed & working fine until the car was driven when it would fail once again.
I am not technically minded but could the combination of harsh ride,aluminium spaceframe & nylon gearing parts in the opensky system which carry a very heavy load all be contributing to this problem.
Personally I feel that this is a design fault & that Audi should be duty bound to fix any of these regardless of the age of the car & warranty status.
Brighton Audi Service Dept have provided excellent aftersales service even though they did not supply the car & have just returned it confident that it is now cured.
If we have no further failures I will endeavour to find out what they did & report any relevant information.
Nice car other than the roof so I`ve just bought a TDi (no opensky) privately.