Headliner Replacement DIY - Step by Step

[threehouse]

Headliner Replacement

Could not find a all-inclusive post so creating one from my lessons learned. I have a 2006 Audi S4 but should be the same for all A/S/RS with B7 platform.
I recommend you take pictures as you go to remember electrical connector locations, see where fabric went to on headliner, etc

1) To start will need to remove the headliner from the car.

a. I would start with removing the rear seat light, the center flip down sunshade by the mirror, sun visor clips (Pass & driver), lights behind sun visors, sun visor (Pass), sun roof control board.

i. Good youtube video: https://www.youtube.com/watch?v=frBVUl9w4-Y&t=272s
ii. Good youtube video (Sun visor lights removal): https://www.youtube.com/watch?v=2dRqTl_6nN4&t=184s
iii. Good youtube video (Sun visor clips removal): https://www.youtube.com/watch?v=zRYsOOzU2Tk

b. Next remove all 4 hand grabs & loosen drivers side sun visor (Mine didn’t have a quick disconnect clip like pass did so I let it hang.)

i.Good youtube video: https://www.youtube.com/watch?v=8JAdQCxBI6w

c. I would remove only the passenger’s side trim piece above the passengers door. The rest you can leave and just flex back to remove / reinstall the roof (NOTE: You can remove headliner without this step as I did but upon reinstall you will need to remove the hand grabs I found out.)
d. I reclined passenger side seat and move drivers all the way back. I removed from driver’s door with rear passengers one open
e. I did not also remove the sunroof sunshade to replace but I think this is process if you elected to also do that

i.Good YouTube video: https://www.youtube.com/watch?v=hGeZIRBr4PU&t=11s

2) Headliner re-work

a. Remove old material (Just peel off)

i. Good youtube video: https://www.youtube.com/watch?v=kZ_bICRvh-Y

b. Recommend you place old headliner on table or saw horses.
c. Recommend you place a old tarp, sheet or painters drop cloth (Plastic) around it as the foam removal is messy and “globs” are sticky (I had to scrap off my garage floor with a large metal ice breaker / scrapper as I skipped this step)
d. Removal of foam:

i. I recommend you buy a large steel bristle type broom from harbor freight. Makes job very easy. You can try to clean it once done or throw out: https://www.harborfreight.com/block-...ush-57291.html

e. Removal of sticky globs:

i. I recommend you buy a 3M adhesion removal spray. Walmart carries it, 1 can will do the job. I sprayed small areas at once, let sit for 1-2min then resprayed areas, wiped off with old rag.: https://www.walmart.com/ip/3M-Adhesi...0&from=/search
ii. I let the headliner hard part sit overnight just in case any of the cleaner spay was present to ensure no solvent left for glue. Now ready for new material

f. I ordered material from headliner magic: https://headlinermagic.net/

i. NOTE: If you select w/ sunroof it gives you enough extra to also do the sun shade cover. That’s only difference.

g. Spray Glue options

i. 3M 77
ii. Permatex headliner spray adhesive (I went with this as it was half the cost of 3M and still got good reviews). Amazon was cheapest place to buy. You will need 2 cans

h. Install of new material:

i. Recommend you swap to new drop cloths vs ones you used for removal of old foam. Also recommend you cover the working surface (table, saw horses, etc) and then have a cloth on the floor also.
ii. Good youtube video: https://www.youtube.com/watch?v=kZ_bICRvh-Y or https://www.youtube.com/watch?v=P83HGoWJSP8
iii. I started with rear section (~1/3), sprayed with glue in both directions on both headliner board and rear of new headliner material (ie foam side), then let tack up for 3-5min after finished spraying
iv. I recommend you have a helper to flip the headliner material on the glue, one person on each side is optimal and helps avoid kinks.
v. Do the same for the middle 3rd and front 3rd.

1. NOTE on the front I recommend you do to the front of the sun roof then start with the front sun flip down shade and work your way out to each side. I didn’t in that area and wound up with a small overlap by the small slip down rear mirror sunshade.

vi. Flip over and cut ~2” around the outside, ensure you cut relief cuts by curves. I wrapped the edges all the way around ~2”. The factory didn’t wrap all areas but I found it cleaner to just do the full liner. (I didn’t use any clamps)
vii. For rear light I cut and just wrapped all extra material onto back side
viii. For sunroof opening I wrapped all edges to the bottom of the metal on the backside.
ix. For front sun roof control unit I just cut all material at the lip of the metal cage around it (No wrap).
x. Once all glued make cut outs for sun visor clips, & lights
xi. I let it dry for 3 days before re-install just to be sure cured. Says 24hrs on glue can.

i. Re-install in car

i. Fairly reverse of removal.
ii. I recommend you put all clips around the sunroof on the headliner side vs the black piece around the sunroof before you put it into the car
iii. Reconnect the rear light
iv. Recommend you start with drivers side, slide under upper trim, then move to pass side. Then start putting back side trim pieces + handles
v. Install rear brake light piece
vi. Install sun visors, clips lights ,etc
vii. Install sun roof control board.
viii. End with pressing sun roof clips together.

j. Enjoy your new non sagging roof!

I know this write up was long but hopefully helpful for step by step with some products resource links. I am on the forums on/off but feel free to leave questions of PM me if you have questions.

[CrickiKaze]

Didn't get a chance to view the links but the Humble Mechanic had a video recently with someone doing this, just to add to context.

[All_Black_A4]

Found this on google. First search result. Used it 5 yrs ago on my first headliner swap in my A4:

https://www.audizine.com/forum/showt...dliner-Removal

Yes its a B6 A4 but still relevant for an B6/B7 A4/S4

[WileyBrill]

I did my 06 S4 Avant, (long roof), two (2) years ago, DIY, (with help from a real-interior guy to apply the new fabric to the shell - I did, all the rest - takeout, strip, re-install.
The Work, demands a long turorial - fact.
Before I started - I printed off all pages from the real-deal Bentley file on my vehicle.
Review and took notes from ALL the you-tube videos I could find.

Removal - follow ALL, the steps, Take Your Time - I took six (6) hours to safely, carefully do it, I used front seat headrests to support - (it is a Long Roof). [seven feet]
Note: where and what order, every piece comes out, fasteners included - they are specific to locations...

Drop cloth - absolutely, under full length table.
Soft/pot-metal trims - Very carefully remove, bend carefully - "You got ONE Shot" at this - and put back...

Pay attention that the Original fabric "JUST" covers the shell - No Over/too much overage - the put back on the metal trim rings is hampered by too much material thickness...
Make "Sharpie" marks to cut to on new fabric, install!

I found, no real good glue/adhesive removal suggestions: On a guess - I used tap/warm water in a trigger spray bottle, soaked an area, used a medium/hard rubber scraper, (like a graphics or "wrap" installer would use - to clean all the adhesive off the shell. (theory was, Europe was into water-based adhesives by 2005)... It Worked fine - the real deal interiors guy was shocked how clean I got the shell !
His mistake - too much/excess - foam/fabric in the cut-outs - let's just say, all the fold over "ears", didn't make the re-install. And, I took my time - the metal is really fragile!

Took me six (6) hours to put back in the vehicle - struggle was a Month, of time had elapsted, so I had to re-learn certain aspects, and use care on put back, lots of care...

My "two cents worth"...

Take your time... Be prepared by as much info as you can find... Take Notes... Witness Mark - during take-off/apart...

WB

[sti2relaxxin]

I'm impressed you all were able to do this yourself. It is a lot of work to reupholster the roof liner, and after a lot of research, I decided to have a local place do it for me. I couldn't believe I found a local place that specializes in roof liners. They did a great job, and also reupholstered the sun roof cover as well. I am glad they suggested it, as the new fabric would not have matched the fabric on the sunroof visor.

For people who have a shop do the work, I recommend watching a good Youtube tutorial (Total Technik has a great one; have to pay for it though), as the trim pieces have to come out a certain way or they can easily break. I would not trust a shop to it, even if they say they are experienced with Audi cars (as mine did).

Here's a link to the Total Technik tutorial: https://www.totaltechnik.com/video/217