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Replacing manual sunroof handle crank gear on Volvo 1986 740

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
1983 - 1992 740
1982 - 1991 760
1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

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Stucco

Replacing manual sunroof handle crank gear on Volvo 1986 740

Post by Stucco »

While tightening up the handcrank on my sunroof, the screw broke off in the gear. Tried reverse drilling it out but in the process I stripped the threads so the replacement screw I had is not going to work in it. Went to the junkyard and found a complete crankgear in a wrecker, but I had to pull mounting hardware, cables and the frame from on top of it to get to it. I'd hate to think I'd have to do the same thing to my car to replace it, and I was wondering if there is an easier way to replace the handle crank gear assembly.

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