Remove the 4 screws holding the "platter" to the lift assembly.
Note that these screws are loctited in so will probably be difficult to remove. Replacement screws are included with the gears.
There are 3 metal spacer plates between the "platter" and the lift assembly, as well as some rubber/foam sealant/insulation.
This shows how the inside gears work - there is a smaller gear that turns inside a larger gear and that gear also spins against the black sleeves that actually move up and down to lift/lower the sunroof.
Remove the center screw.
Lift out the long retaining spacer.
Turn the crank handle on the bottom side to thread up the big outer gear.
Once you thread out the bigger outer gear, the smaller inner gear will simply lift out.
This just shows how the crank handle is attached and aligns with the regulator assembly.
This shows the inner gear that the crank handle turns - this toothed gear is what the small inner gear sits on, and it is notched for alignment of the inner gear.
We found that the assembly goes back together with the crank handle back in it's proper position if the toothed gear is aligned as shown here.
Start by pulling up the black plastic risers a little, maybe 1 inch or so.
Insert the smaller aluminum gear down into the regulator, aligning it with the notch, and press down on it so it seats all the way down in.
NOTE: Apply white lithium grease to all threads of the aluminum gears (inner and outer) before installing to ensure smooth operation and long life of the gears.
With the inner gear in place, pull up the black plastic risers all the way.
The big outer aluminum gear is threaded on the inside only on one end - this is the end that will go into the regulator first, to mate with the smaller inner gear.
Thread it into the black riser (fully extended so the big gear does not yet engage the smaller inner gear) until it is threaded down nearly flush with the top of the black riser.
Looking down through the outer gear, turn it so the its inner gearing aligns with the smaller gear in the bottom - basically so when you push the big gear and plastic riser down, the 2 aluminum gears will be lined up to engage.
Press the black riser and outer gear down until the 2 aluminum gears are at the point of engagement.
Turn the crank handle to engage the two gears, and continue to press the risers down, not allowing the outer aluminum gear to turn. You want the inner gear to pull the assembly down, but you do NOT want the inner gear to get pulled up off of the cog driving it.
Once you have threaded the whole lift assembly back down, reinsert the long retaining spacer and press it down into the inner aluminum gear until it is flush.
You may have to re-orient the retaining spacer until it drops fully down into place.
Rethread the long center bolt into the assembly and tighten.
At this point you should be able to crank the lift assembly up and down.
Using the new screws, reattach the "platter" to the lift assembly - this is best done with the lift assembly down so as not to stress the plastic gearing on the black riser pieces. Remember to include the metal spacers that were originally between the riser and "platter".
