How to Install a Sun Roof in a Mercury Cougar
The simplicity of the roof design on the Mercury Cougar makes installing a sunroof less prone to problems than many cars. Installing a sunroof on a Mercury Cougar requires special tools and precision cutting skills. Late Mercury Cougar models with a common factory sunroof problem can replace the factory unit with a 20 inch by 36 inch aftermarket unit without cutting the roof.
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Things You'll Need
- Sunroof kit
- Sheet or tarp
- Screwdrivers
- Drill and bits
- Sheet metal shears
- Metal file
- Metal primer
- Sealant
- Razor knife
Instructions
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1
Prepare the work area by laying out the required tools and sunroof parts. Cover the interior with a sheet or tarp to protect the seats and dash of the Cougar. Remove the headliner and support panels.
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2
Hold the shade tray to the interior of the roof and make sure there is at least 4 inches of clear space on each side. Use a screwdriver to make a dent in the roof at each corner of the tray.
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3
Tape the template to the rooftop using the dents as a guide. Drill a starter hole through one of the dents and cut the roof with metal shears following the template exactly.
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4
Smooth the edges of the opening with a file and test fit the sunroof frame. Make and required adjustments and coat the edges with metal primer to inhibit rusting.
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5
Clean the bottom of the sunroof and run a bead of sealant around the lip. Set the sunroof frame in place and connect the clamping ring and screws taking care not to overtighten any of the assembly.
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6
Wipe off any excess sealant and assemble the rest of the sunroof by following the manual. Replace the headliner and support panels using a razor knife to make any alterations.
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Tips & Warnings
Thieves often use a loose sunroof for access to a car; always place the sunroof in the fully locked position when away from the vehicle.
