Need advice on leaking sunroof. Would appreciate any help. 1996 960 glass electric moonroof.
I have a leak that runs down the A pillar on the driver's side. I have checked the gutter drains (particularly this corner) by pouring a measured amount in the gutter at this location and collecting almost the same amount at the drain site behind the left front wheel. It drains rapidly and I think the drain is clear. I have cleaned and resealed the glass to hard rubber gasket seal but of course the outer rim of the seal is not designed to be totally waterproof but looks like it fits pretty snug. When I soak the closed roof with a hose for 15 minutes (or a long hard rain) I notice wetness at the top of the interior cover of the A pillar. The water appears to continue down the pillar and into the driver's floor.
I have partially removed the pillar cover and can get my finger inside the pillar to touch the gutter drain. It appears that the leak is coming from a location away from the gutter drain and more toward the center at the front of the sunroof gutter. I am not able to inspect this area of the gutter because the pop up wind deflector blocks my view and access.
1. How can I remove or reposition the wind deflector?
2. The cover below the wind deflector has two copper set screws that I can get to but I suspect it has two more covered by the wind deflector. Is there any caution or trick on removal?
3. Does anyone have experience with the gutter itself leaking?

Thanks in advance to any member who might offer help.

I have a similar problem... '97 960.
At first I had a drip coming from the dome light, as the water would collect on the headliner causing it to sag a bit and then shorting out the dome light assembly (I finally got new circuitry for that at a junkyard.) I guess I need to replace this headliner or live with the slightly mildewy smell..

Anyway, after I took it to Volvo to try to get a stronger seal last January ($$-they told me they have to replace the glass too since the rubber is sealed on it, thanks volvo...), I started getting water under the passenger side carpet (and in the back seat too depending if I parked uphill or downhill). I finally took out all the carpet and during the next big storm I sat and waited to figure out how the water was getting down there. Anyway, water from my sunroof was escaping the outermost trough (where it's supposed to collect) through a worn rubber seal (wear and tear of opening/closing?) and travelling elsewhere. (Specifically, in the NE corner of the sunroof) Water was dripping onto the sunroof cover as well as moving across the ceiling towards the top of the passenger door. (I have wrinkled apholstery there where the water is getting in.)

It seems my drain pipes are working fine, so the water is getting to the floor another way- it's sliding down the rubber gasket of the door frame (this takes a while, so it's only noticeable during a prolonged rain and is why hoses and carwashes cannot recreate the scenario). When it reached the curve at the bottom of the door, gravity moves it to the floor of the car... Anyway, after it rains again, check to see if that's wet...

In the meantime I will keep the sunroof cover open and put a small rag in that corner- this way water drips on to my passenger seat instead of travelling down my door frame...

I'm not sure how to fix this leak in my sunroof though... I don't want to try and detach it, it seems too tricky. I'm tempted just to close it forever with some silicone...
Hope this helps-
Carl

Have you seen this info: http://www.volvoclub.org.uk/faq/BodySunroo...ml#SunroofLeaks

I have the same symptoms and will take a look this weekend. It looks like easy removal of the glass with frame and clean up and re-seal the rubber seal between them.

I think I fixed it. The glass piece comes out very easily - 4 8mm hex heads (remove plastic trims inside so you can use a socket wrench). In my case the rubber trim had been re-siliconed before, but the silicone and glass hadn't bonded very well and now water could pass between them. I cleaned off all of the old silicone and sealed with the stuff I bought for sealing the upper and lower cylinder heads (some kind of high temp silicone adhesive). I planned on using a product called 'Seal All', but found that I was out of stock. This has worked every time I've used it on similar problems.

Now I'm waiting for a good downpour, or maybe enough time to take it for a wash.

Me too. I finally paid an auto shop that specializes in sunroofs to diagnose it. Of course water is meant to seep into the grooves surrounding the sunroof and between the roof and then to drain into the 4 drain holes. Turns out the rubber lining the perimeter of the glass had some gaps or cracks (they tested it by applying foam around the edge and then pumping air from below; much easier with the headliner taken out. The area where there was a gap bubbled right up, just like testing for a leak in an innertube). That's why water was seeping under the glass going everywhere it wasn't supposed to and of course soaking the headliner and eventually the carpets below.

So with this in mind, my solutions are to every once in a while check the silicone and apply as needed, install a used working glass (of course with the rubber around it), around $200 used I believe. But now I shouldn't have to seal it forever since I know where the problem is...