This was supposed to be a quick and dirty how-to for replacing the slides on a CC sunroof. Unfortunately, for me, it wasn't so quick and dirty. I had the headliner and the sunroof frame down in about hour. Had the slides replaced and was ready to reinstall in another 30 minutes. Hung the frame back up and started putting everything back only to realize I had messed up reinstalling the cable tubes. Had it on top of the frame instead of under it, but had already riveted it back on.
Now is a good time to stress that you should not get in a hurry with this project and you should definitely not take ANY shortcuts.
Guess what! I got in a hurry and I took a shortcut. I didn't have any more of the right size rivets, so rather than drill the rivets back out and do it right, I bent the tubes out to get them below the frame. I AM STUPID! NEVER DO THAT!
Now would be a good time to tell you that the instructions specifically tell you to be careful with the end caps and cable tubes because the break easily.
See, it's right here
Guess what! I broke both sides. Guess what else! You can't buy those from Ford without buying the whole frame. Guess what else! Retail is $1020. (ANWBL has it for $672). One more little tidbit is that salvage yards don't generally save the frames and cable tubes, just the glass.
Anyway, some actual usable information is that the slide kit found here>>
Expedition / Navigator / SuperCrew Sunroof Information
works perfectly. Just be more careful than I was. To replace the slides you have to drop the headliner and the frame. The headliner is pretty straightforward, everything that looks like it has to come off, does. Visors, center overhead console, grab handles, coat hooks, interior trim at sunroof, A, B and C pillar trim. B and C trim can just be pulled loose and worked around, but seat belt connections have to be removed. The headliner will not come out without removing seats or rear window. I chose to work around it and just drop it down. Strategic use of the seat reclining is helpful. Once the headliner is down you can get to the motor and frame bolts pretty easily. Remove the glass first though. There are 4 torx bolts to remove and then it will lift out the top. There are 11 frame bolts and 3 motor bolts (remove the motor first). I did all of this by myself, but I'd recommend an extra pair of hands if you can get some. You will need to drill out the 6 rivets (3 each side) holding the end caps and cable tubes to the frame. This can be done prior to dropping the frame, but I don't know that it really makes that much difference. Then remove the rear drain trough, 2 small screws, one on each side. Then carefully pull the end caps away from the frame. They are stuck on with a rubbery adhesive so it's a little scary at first, but they'll come off. Remove the old slide pieces and replace with the new stuff and reverse the process to put it back together. If you're careful, not in a hurry and don't take shortcuts, you should have a functional sunroof again. The kit comes with instructions, but I thought I'd give a little insight on what NOT to do.
Here are some more pics I took off the process.
Broken parts and new parts.
Patch job on drivers side end cap with epoxy.
Patch job on passengers side.
As shown, I was able to epoxy mine back together, but I don't trust it to last. I'll be trying to find a replacement cable tube/end cap assembly and go back in at some point.