Plastic gear is prone to failure. A good way to prevent this is to keep the sunroof oiled, gaskets and track (thats what Hebasto told me). Also, once it's fixed.. don't pop it up ALL THE WAY, or retract it ALL The way. SOmehting about getting to the final point where it can't open no more and the torque required to budge the glass just strips the stupid plastic gear. Once you remove that upper console, you'll see 3 torx bit screws.. think they are t-27 (not positive). After those come out, just pull down on the motor (not hard, it'll come right off) and you'll see the metal gear sticking down. Just turn it with a pare of vice grips with a rag and you can close it that way. I will get mine fixed.... it's covered under warranty for me.
Someone tried to reproduce the plastic gear out of metal, but failed at it.
Oh yeah.. welcome to CEG. You'll find most of us very usefull.
