Sunroof Motor

This procedure covers the removal and replacement of the sunroof motor on a 1966 Chevrolet Corvette. The C2 Corvette's optional power sunroof system uses a reversible electric motor mounted in the headliner area.

Warnings

Tools required

Parts

• Sunroof motor assembly × 1 — Use OEM specification or reproduction Corvette sunroof motor
• Motor mounting gasket × 1 — Use OEM specification
• Wire connectors (if damaged) × 2 — Butt splice connectors, 16-18 gauge

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable and secure away from battery post.
3. Verify sunroof is in fully closed position before proceeding.
4. Protect interior surfaces with clean towels or drop cloth to catch debris during headliner work.
5. Mark or photograph wire routing and connections for reference during reassembly.

Procedure

1. 1

   Remove sunroof control switch bezel
   Locate the sunroof control switch on the center console or dash area. Use a flathead screwdriver wrapped in masking tape to carefully pry the switch bezel from its mounting location. Disconnect the wiring connector from the back of the switch by pressing the release tab and pulling straight back.
2. 2

   Access headliner in sunroof motor area
   From inside the vehicle, locate the headliner area above the driver's seat where the sunroof motor is mounted. The motor is typically positioned forward of the sunroof opening on the driver's side. Carefully pull down the headliner edge to expose the motor mounting area. Use a trim tool if necessary to release headliner clips without tearing the material.
3. 3

   Disconnect motor wiring
   Locate the two-wire power connector leading to the sunroof motor. The wiring typically includes a positive and negative feed from the control switch. Disconnect the wire connector by pulling apart the bullet-style connectors or cutting the wires if they are spliced directly. If cutting, leave at least 4 inches of wire on both motor and harness sides for reconnection. Label wires with masking tape to identify polarity.
4. 4

   Disconnect drive cable from motor
   The sunroof motor drives the sunroof mechanism via a flexible drive cable with a square or hex end. Locate where the drive cable connects to the motor output shaft. Remove the cable retaining clip or clamp using needle-nose pliers. Carefully pull the drive cable housing straight back from the motor to separate. Support the cable to prevent it from retracting into the headliner channel.
5. 5

   Remove motor mounting fasteners
   Remove the 3 mounting bolts securing the sunroof motor to its bracket using a 7/16" socket. The motor is typically mounted to a stamped steel bracket that attaches to the roof structure. Support the motor with one hand while removing the final bolt to prevent it from falling.
6. 6

   Remove motor and bracket assembly
   Lower the sunroof motor and mounting bracket as a unit from the headliner area. Maneuver carefully to avoid snagging on headliner material or wiring. Inspect the motor mounting bracket for cracks or damage. If the bracket is damaged, it must be replaced with the motor.
7. 7

   Inspect drive cable and mechanism
   With the motor removed, inspect the drive cable for kinks, fraying, or damage. Rotate the sunroof mechanism manually by turning the drive cable input to verify smooth operation. If the mechanism binds or feels rough, the issue may be with the sunroof tracks or guides rather than the motor. Clean any debris from the cable housing connection point.
8. 8

   Prepare new motor for installation
   Unpack the replacement sunroof motor and verify it matches the original in mounting configuration and output shaft design. Install a new motor mounting gasket if one is provided. Test the new motor operation before installation by briefly connecting it to a 12-volt power source using jumper wires. Verify it rotates smoothly in both directions by reversing polarity.
9. 9

   Install motor and bracket assembly
   Position the new motor and bracket assembly into the headliner mounting location. Align the mounting holes with the roof structure brackets. Thread in the 3 mounting bolts by hand, then tighten in a crossing pattern using a 7/16" socket. Ensure the motor is secure and properly aligned with the drive cable path.
10. 10

    Connect drive cable to motor
    Guide the drive cable housing into the motor output connection. Push firmly until the cable square or hex end engages fully with the motor output shaft. You should feel a positive engagement. Install the cable retaining clip or clamp using needle-nose pliers. Tug gently on the cable housing to verify it is locked in place.
11. 11

    Reconnect motor wiring
    Reconnect the motor wiring using the original connectors or, if wires were cut, strip 3/8 inch of insulation and connect using butt splice connectors with proper polarity. Refer to your earlier labels to ensure correct positive and negative connections. Crimp connections securely and tug-test each wire.
12. 12

    Reinstall headliner and switch
    Carefully tuck the headliner back into position and secure any clips that were released during disassembly. Reconnect the sunroof control switch wiring connector and press the switch bezel back into its mounting location until it clicks into place.
13. 13

    Reconnect battery and test operation
    Reconnect the negative battery cable. Activate the sunroof control switch to test motor operation in both open and close directions. Listen for smooth, consistent motor operation without grinding or hesitation. Verify the sunroof opens and closes fully without binding. If operation is reversed, the motor wiring polarity needs to be swapped.

Reassembly

1. Ensure all headliner clips are fully seated to prevent sagging.
2. Verify no wiring is pinched between mounting brackets or body panels.
3. Test sunroof operation through several full cycles to confirm proper installation.
4. Clean any fingerprints or marks from interior surfaces.

Verification

• Sunroof operates smoothly in both open and close directions without hesitation.
• Motor runs quietly without unusual grinding, clicking, or binding noises.
• Sunroof fully closes and seals properly against the weatherstripping.
• Control switch operates motor correctly with proper directional response.
• No electrical short indicators such as blown fuses or inoperative circuits.

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