MerlintheMad
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So what do you think is going on with this flaw? I'm going to guess that assembly had a "glitch" phase (or possibly more than one), wherein the entire sunroof assembly was compromised somehow. It can't be insertion into the roof line, or else the new sunroof would not have been necessary: Kia would have simply uninstalled the existing sunroof frame and reinstalled it correctly. So the noises must be caused by a "loose" assembly of some kind. Possibly the sunroof assembly plant or station went through a retool when the problem was caught. Replacement sunroofs are all made to the tighter/retooled specs. (How would we ever find out or know? Only when Kia did not catch a flaw like this soon enough to prevent thousands of Stingers from going out with the faulty sunroof assembly; I think it is encouraging that so far there have been very few "recalls" of any kind.)its been perfect since it was replaced , I cant believe the difference , it tightened up the structural integrity of the whole cabin , and 17yr old son proved to me how much better the stereo sounds too !!
(edit to ask: what is the build date of your car?)