DIY Network

Headliner Repair: Introduction and Prep From "Weekend Mechanic" episode WKM-302

Bruce Bonebrake shows how to remedy one of the more irritating of all automotive problems -- a sagging headliner.

In this episode, Weekend Mechanic host Bruce Bonebrake shows how to repair a sagging headliner. The old headliner is removed from the vehicle, repaired with new covering and reinstalled. Since our project vehicle has a sunroof, the liner of the sunroof is replaced as well. In this first segment, Bruce introduces the problem and preps the vehicle for the repair.

Materials:

In addition to standard auto-mechanic's tools, some of the specialty tools that will be needed for this project include glue gun, torx scredrivers, steamer, whisk broom, and heavy-duty scissors. Safety equipment includes ear protection and eye-goggles or protective glasses.

advertisement

The problem: Our project car, a 1990 Volvo 760 Turbo, has one of the more aggravating problems that can occur in a vehicle's interior: a sagging headliner. This sagging typically starts at the dome section of the car's ceiling and works outward as the fabric cover separates from the foam backing on the contoured board. Though some people try temporary or partial fixes using tacks or T-pins, that solution is never permanent, and sticking pins throughy your headliner could damage electrical wiring. Permanently fixing this problem, and doing it the right way, requires removing the headliner board from the vehicle so that new headliner fabric can be glued on. The headliner should never be repaired inside the car.

DIY Difficulty Rating for Repair: This job is fairly straightforward, and something that seasoned or novice do-it-yourselfers can undertake. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. Depending on the severity of the difficulties encountered, this project should be one that can be finished in a single weekend. Allow yourself about 12 hours to complete this project. Estimated cost for the repair is around $100. The trickiest part of the procedure is removing the headliner board from the vehicle without breaking it.

Important: Included in this episode are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Prep Work

• Begin by removing the front seats from the vehicle (figure A). This will make it much easier to get the headliner board out of, and back into, the car. If you can't remove the seats, then remove the headrests from the seats, and recline the seats as far back as possible.

  With the seats removed (figure B), there is more room to work. In order to get the headliner out, it will be necessary to remove the interior side-trim pieces, sun visors, and the dome light assembly.

  Figure A

  Figure B

  
  

  	Figure C
  	Figure D

  
  In some cases, the headliner may not merely be sagging, but may actually come detached from underneath trim pieces (figure C). This can interfere with driver sight-line and cause a driving hazard.

  Since our vehicle has a sunroof that is also covered in fabric (figure D), the sunroof panel will need to be removed and re-covered as well. (The sunroof has a vent panel inside the sunroof headliner.)

  While the sunroof is off, it's also a good time to inspect the working parts, cabling and drain holes to make sure that they are all in order.
  

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Automotive Detailing: A Complete Car Care Guide for Auto Enthusiasts and Detailing Professionals
1557882886
Don Taylor
To order this title from Amazon, click here.
H.P. Books