Sunroof Cassette

Cassette means 'little box' in French, and refers to anything which comes in a little box, and as cars are modular these days, that can be a great many things.

However, when we say 'cassette' we are usually referring to the sunroof unit, which sits in a plastic tray which serves as a drainage trough.

The sunroof panel may have weather striping around it, but usually this isn't designed to be waterproof. Instead, water passing this drains into the cassette. From there, there are two or four drainage pipes which let the water drain to the bottom of the car.

If those pipes become blocked, which is extremely common, the cassette will fill with water, and then when you drive the car the water will slop over the sides of the cassette and pour through the headlining.

What it means

A sunroof cassette is the hidden structure that makes a modern sunroof work. Rather than just a glass panel in a hole, most cars have a self-contained cassette - a metal or reinforced frame that bolts or is bonded to the underside of the roof skin. This cassette carries the sliding or tilting mechanism, the glass, inner trims, gutters and the outlets where drainage pipes attach. Any water that gets past the outer seal is meant to fall into the cassette tray, run along shaped channels and disappear down the drain tubes to exit safely under the car.

Why it matters

• Major player in sunroof leaks: If the cassette drains block, the frame corrodes or the joints crack, the tray can overflow and water will escape into the headlining, A-pillars, B-pillars or boot area instead of going down the drains.
• Affects multiple leak points: Problems with the cassette can show up as wet front or rear footwells, damp headlining, water in pillars or even in the boot, because the drain tubes run through several parts of the body.
• Labour intensive to access: The cassette usually sits above the headlining, so proper inspection or replacement often means removing interior trims and lowering or taking out the headlining - not a quick job.
• Part of the roof structure: On many cars, especially panoramic roofs, the cassette is a structural piece. Poor fitting or corrosion can affect stiffness as well as water management.

Where you will see it

You will see sunroof cassette mentioned in leak reports, bodyshop notes and technical bulletins. Typical comments include sunroof cassette gutters blocked, sunroof cassette leaking at rear corner, cassette corroded around drain outlets or remove headlining to access sunroof cassette and drains. It is a common focus when owners report water from the overhead console, wet A-pillars, mystery drips from interior lights or damp carpets under a car with a sunroof or panoramic roof.

Context

The sunroof cassette sits at the centre of the roof water management system. Water lands in the sunroof tray, flows along the cassette's built-in gutters and disappears into the drainage pipes that run down the pillars and exit under the car. The outer glass seal is mainly for wind noise and appearance - a small amount of water getting past it is normal. Leaks arise when drains block, the cassette-to-roof seal fails, joints crack, or the frame becomes distorted or rusty. A proper diagnosis usually involves dropping parts of the headlining, checking the cassette, testing the drains and watching from inside while water is applied around the sunroof from above.

Common mistakes

• Blaming the outer sunroof seal for leaks when the real problem is blocked cassette drains or water escaping from a corner of the cassette tray.
• Trying to seal the glass shut with silicone instead of cleaning and unblocking the drains and checking the cassette and its joints.
• Pouring large amounts of water into a sunroof that is known to have blocked drains, which can overwhelm the cassette and flood the interior.
• Drying wet carpets and headlining without inspecting the sunroof cassette and drain paths above, leading to repeat leaks with the next heavy rain.

Written by Danny Argent. Last updated 08/12/2025 16:23