BMW E39 Headliner & Sunroof Cassette Replacement DIY

This video demonstrates how to remove and reinstall the headliner, A/B/C pillars, and complete sunroof cassette in the BMW E39 5 series.
Parts Required:
(1) Sunroof cassette: 54128250048: tinyurl.com/2s2fr9pn
(1) Sunroof motor: 67618377939: tinyurl.com/yxtcxs3r
Torques:
Sunroof glass to cassette: 4x T25 screws, blue loctite, 53in/lb
Sunroof motor to cassette: 3x T25 screws, blue loctite, 25in/lb (center screw is longer)
E39Source website: www.e39source.com
Help support E39Source by donating: www.e39source.com/donate
DISCLOSURE: This post may contain affiliate links, meaning when you click the links and make a purchase, we receive a commission.

[@Pfalzgarage]

I have a sunroof in mine that won't tilt anymore, and this is going to be immensely helpful.

[@MultiAna96]

Amazing attention to detail as always👌

[@brandontkeenan]

Another great tutorial. When I refreshed the interior on my E38 last year, it was largely the same procedure to get the pillars and headliner out. Unfortunately, only 1 tab out of all 8 pillars were not broken. I found removing the rear bottom seat and then lowering and tilting the passenger seat back as far as it would go gave enough room to get the headliner in and out of the passenger rear door by myself without any difficulty or flexing of the headliner. Also, this particular car looked good but definitely on my car the disintegrated orange glue/foam on the pillars and headliner was a complete mess. I mostly mitigated it by taping the door trim down in 2in painters tape and covering the seats with plastic to make cleanup easier.

[@TheBrandoAnderson]

Amazing video! Our 540i sport has a disappointing headliner. There's a beautiful one at the junk yard nearby. We are going to attempt to pull it along with the sunroof assembly. Wish us Luck.

[@The-truth-is-valuable.]

Brilliant and in time, as I need to do mine. Thanks Ryan.

[@bighitadam]

14:49 Important note: once you are popping back the headrests, always support you headrest motor from the bottom. (Under seat back cover) Without support, there is a good chance the force will broke the small tabs which are securing the whole motor assembly to the seat!

[@marisp.4868]

Wooaa, thanks! Very relevant for summer time

[@CommanderAki]

Wonderful tutorial, it’ll be really helpful once I’ll be retrofitting autodimm inside mirror and alarm system and also renewing the headliner, thank you so much for the guide :)

[@OtoGodfrey]

Hell yeah. I got two space sun roofs but only need one.. need to fix the howling boiling tea pot sounds that starts at 240kmh+ on Autobahn.

[@jaygrosse8365]

Another excellent video Ryan. You are a gifted teacher. Do you recommend any regular preventive maintenance on the sunroof mechanisms, such as cleaning and/or lubricating the sliding portions with silicone spray, blowing out the drain lines, etc?

[@DK-421]

Reasons why I plan on doing a sunroof delete at some point. 😂

[@kevinsebok5128]

Hi Ryan! Thank you so much for your good video :D I have slight problem, In the front between the sunroof and the roof i have a very nice gap(like 1mm), but at the Back i have a really big gap (like 5mm). How can i adjust it?

[@E39Source]

This video covers adjusting the sunroof glass, towards the end. You'll loosen the Torx screws, adjust the glass, and tighten again until it's set right.

[@kevinsebok5128]

Thank you so much! ^^

[@TheBestGamer25]

I cant get the c shape in back of the headliner inside the things. You have any tips?

[@E39Source]

The back of the headliner at the rear glass? It must start there, then work forwards.

[@xhf8yxhf8y9]

What was the issue that required a whole cassette replacement, rather than repair??

[@E39Source]

We took a more comprehensive approach seeing that most of the plastics were heavily worn/brittle. You can purchase the rebuild kits, but if you need them all-- there is something to be said for replacing the entire cassette.

[@TheBestGamer25]

Is the seatbelt tx45 or tx50? Because I seen one video that said tx45

[@E39Source]

They are T50s.

[@PursuitMode2011]

I did the same exact job on my E39 540i and because of it my hair and facial hair for my beard turned white. Never again. One of the most frustrating jobs I’ve ever experienced in my life. Horrific from A-Z

[@Markjw25]

Did this job last year. Real fun, not! Getting the glass realigned was so tedious..never again lol.

[@kianacaylen9186]

Promo`SM