Volvo - Sunroof - Gap Filler Repair Kit (SPA V90, XC90, S90, V60, XC60, XC40)

The Original Sunroof Gap Filler Kit

Form&Function Design introduced the first gap filler solution for the widespread sunroof seal shrinkage issue affecting Volvo SPA platform vehicles. Since 2024, this kit has been tried and tested by thousands of Volvo owners, independent repair shops, and Volvo dealerships worldwide.

The factory-installed seal contracts over time, creating gaps that allow water and debris into the drain system. Left unaddressed, clogged drains can cause significant water damage to interior electronics. This issue is documented in Volvo Technical Journal TJ 35503.3.0, "Panoramic sunroof, sealing strip has a gap" (read the official Volvo bulletin).

Why This Kit

• The original design, developed and refined through real-world testing
• Trusted by Volvo dealerships and independent shops for customer repairs
• Over 3,000 kits sold worldwide
• Designed and manufactured in Canada
• Beware of imitations using copied designs

A Permanent Solution

Replacing the factory seal does not solve the underlying problem. Replacement seals are made from the same material and will shrink again over time, making them a recurring maintenance item rather than a permanent fix.

This kit eliminates the need for repeated seal replacements. As the seal continues to shrink, larger inserts from the kit can be installed to maintain protection. The result is a long-term solution that adapts to ongoing seal degradation.

Benefits

• Prevents large debris and dust from entering the sunroof drain system
• Prevents large amounts of water from entering the sunroof drain system
• Eliminates wind noise caused by the gap
• Fills the gap to restore a clean appearance

Kit Contents

VOLKIT1 - Normal Kit (Most common gap sizes)

VOLKIT1-L - Large Gap Kit

VOLKIT1-F - Full Kit (Normal + Large)

Both kits combined under a single part number. The Full Kit includes the complete Normal Kit (6/10/15mm) and the complete Large Kit (15/20/25mm), covering every gap size from 6mm to 25mm. Having the full range on hand means you can move up to a larger insert as the seal continues to shrink, without ordering again.

*Custom lengths available - contact us for more information.

For Shops and Dealers

Individual pair sizes available in bulk: Purchase bulk quantities here

Specifications

• Material: TPU (Thermoplastic Polyurethane)
• Shore Hardness: 95A
• UV Resistant: Yes
• Weather Resistant: Yes
• Country of Origin: Canada

Installation

Avoid removing the seal from the sunroof as it may be difficult to reinstall correctly. Follow these steps instead:

1. Choose the right size gap filler. Slightly longer is better.
2. Push the seal back with your fingers along the track. A small amount of silicone lubricant can help.
3. Insert the gap filler onto the glass, ensuring it snaps onto the lower and upper channel.
4. Pull the seal back onto the gap filler until it sits flush.

Each insert is scribed with LEFT or RIGHT on the bottom, allowing for quick identification during installation and confirming correct orientation.

Installation time: 2-5 minutes

Dropped Insert Recovery

If an insert is accidentally dropped into the sunroof channel during installation, it can be retrieved directly through the gap using long needle-nose pliers, or from inside the vehicle by removing a simple trim piece.

Compatibility

This kit fits the following models:

• Volvo XC90 (2015-Present)
• Volvo XC60 (2017-Present)
• Volvo XC40 (2017-Present)
• Volvo S90 (2017-Present)
• Volvo V90 and V90 Cross Country (2017-Present)
• Volvo V60 and V60 Cross Country (2018-Present)

OEM Seal Part Number: 32342701 (current part; supersedes the earlier 31484660).

A Note on Warranty Seal Replacement

Vehicles under warranty may qualify for seal replacement under Volvo TJ 35503.3.0 (NHTSA MC-10212893-9999). However, there are considerations worth noting:

• Replacement seals use the same material and will likely shrink again over time
• The replacement procedure requires sunroof glass removal, which carries risk of improper reinstallation or damage to adjacent seals
• There have been reported instances of water intrusion following seal replacement due to other seals shifting during the glass removal and reinstallation process

This kit provides a non-invasive alternative that does not require glass removal and can be installed in minutes.

Sunroof Care Guide

Want the full picture before or after you install? Our free Sunroof Care guide walks through how the system works and how to keep it leak-free:

• Volvo SPA sunroof care (2015 and newer)
• Why sunroof seals shrink
• Cleaning and testing your sunroof drains