My Headliner R&R Experience

[Mark Pollan <Mark.Pollan@mci.com>]

I posted the below messages some time ago.  The first message details
my removal process.  The second is installation.

HTH,

Mark Pollan, '86 5KCSTQ 279K Miles

P.S.  It has been about 9 months and the headliner is holding strong.

**********************

Subject: Headliner Removal and Observations

Hi all:

Pulled out the molded headliner in my 5KCSTQ this weekend.  Wasn't
nearly as bad as I expected to get it out.  Removal resulted in some
very minor tearing of the cardboard mold.  I plan on taking it to an
upholstery shop and having them cover it.  I'll put it back in myself.

The front part of the headliner is held up by the trim and glued in only
two place.  Actually there is some high density foam glued to the liner
and the roof.  I used a sharpened pry bar to work through the foam
as close to the liner as possible.

There is no adhesive until you get about 12 inches behind the sunroof.
That is some sticky stuff.  I couldn't beleieve how adhesive it was
after 12 years.  Anyway, slowly worked bakwards cutting with the pry
bar and levering by hand to minimize damage to the cardboard.  With
some gentle persuasion the whole thing came out the back door.

I know there are a lot of saggy headliners out there so I will post
the final results when I'm done.  At $400+ for a new headliner I figured
this was worth a flier.  Now I can alomost afford those eurolights
with what I saved (optimistic aren't I).

Mark Pollan '86 5KCSTQ 252K Miles



>How does the headliner separate from around the sunroof?   
>Do you just pry up the metal tabs?

Yep, that's how I got it out.  I had to loosen the sunroof rails to
get to the tabs.  You can access the tabs on the front and back of
the openning without loosening the rails but not the side tabs.

After I went through this frustration, I ended up taking the entire
sunroof assembly out per Bentley since the material on the sunroof
was pretty trashed too.

>Also, according to the Bentley you need a special tool
>to remove the covers of the rear sides (the part by the rear window going
>from the speaker deck up to the roof), is this true, how about a work
>around?

I didn't take these off to get the headliner out.  I will need to so
I can get it back in so if you hear privately please let me know.

$200-250 for the whole enchilada is a bargain.  I got quotes for applying
new material to the shell for this amount.  Found a place that did
it for $110 and the did a really good job.  I have yet to find the
time to put the headliner back in.  Be very careful if they have not
done an Audi.  It is not hard but pretty involved.
**********************

Hi All:

After _months_ of procrastination I finally put my newly recovered
headliner shell back in this weekend.  I took my sweet time and it
looks great:).

Steps I took are as follows:

1)  Remove sunroof mechanism.
2)  Remove Steering wheel.
3)  Remove rear seat bench and seatback.
4)  Remove rear cargo shelf and all trim parts.  I pulled all the interior
    trim parts that even remotely looked like they might get in the
    way.  Didn't want to have an adhesive slathered headliner rubbing
    up against trim parts.
  Note:
    I tried removing the D-pillar trim.  The trim clips were no problem
    but the rear window sealant sure was!  Seems like somebody on the
    assembly line was a tad generous with the sealant and glued the
    trim pieces in along with the window.
5)  Recline front seats all the way back and lower as much as possible.
6)  Remove rear view mirror.
7)  Slide headliner shell in car.  I actually went in through the front
    door towards the back.  Bentley calls for going in the rear door.
    With the steering wheel off it goes in much easier through the front.
8)  Spray shell with 3M Super Trim Adhesive according to instructions.
9)  Reach in through sun-roof openning and lift headliner into place.
    Use the aluminum retaining ring and clip a few of the clips to
    hold it in place.  Bentley says to first attach by screwing in
    the sunvisor clips.  Going through the sunroof assures proper allignment.
10) Attach sun visor clips.
11) Press rear of headliner up against roof.  I wedged a 2 foot long
    piece of 2x12 up with a 2x4 to get a good contact patch.
12) Put all those little trim pieces back on.

HTH and feel free to drop me a line with any questions.