After I re-upholstered my headliner, I noticed how bad my sun visors looked. Even though I picked a similar color headliner, the visors were faded and worn. I searched the forum for information, but found very little.
Here is step by step instruction for the process with pictures for the disassembly (got a new phone and did not forward second batch of photos before I gave up my old one). I think that re-assembly is pretty straight forward.
1. Use a T25 driver to remove the sun visor and disconnect the wire. Take it somewhere comfortable to work on it.
2. Use a large screwdriver to break the epoxy joints. They are about 3/4" in from the edge all the way around the visor(red arrows). Be careful to break as few of the little teeth around the edge as possible because they are what holds the material on. When you are done, it will open like a clam shell. Do not try to force it open any further than mine is in the picture, it is not necessary.
3. Remove the extenter piece. There are three tabs that you can slide a screwdriver under to get them loose (red circles). The entire thing will pull out but will catch just before it come loose. Lift it away from the sun visor and it will pull the rest of the way out.
4. Remove the mirror. There are three tabs that you will need to use a screwdriver to get loose (red circles). Once you get them free, flip the mirror up to see the bottom of it. Use a pair of wire snips to cut the wires to the lights as close to the bottom of the mirror as possible. Tape the wires across the middle of the opening so you can find them later.
5. On the very end of the visor, there is a wire rod that goes through the plastic piece that is used to clip to the sun visor bracket. Reach in at the red arrow with a pair of needle nose plyers and pull the rod out. This will release the piece of plastic and you can remove the fabric from the entire sun visor.
This is where I lost the rest of my pictures...
6. Cut a piece of headliner material big enough to cover both sides and leave a couple inches of extra all the way around. Cut a slit in the material on the side where the metal piece is the attaches to the ceiling. The slit should stop about a quarter inch before the metal piece meets the plastic of the visor.
7. At this point, I used a light coat of spray adhesive to help me keep everything in place, but the adhesive is not used to hold it on when it is finished. I sprayed the material, but stayed away from the area around the slit just to make sure that I did not make a mess on the metal piece that I would have to clean up later. I let the adhesive sit for a few minutes then wrapped it around the open sun visor being careful to press it into all of the curves.
8. Trim the material all the way around the visor so that it reaches almost to the epoxy joints inside, but does not interfere with them. It definitly needs to reach over the teeth. The adhesive that is on the material should be enough to make most of the material stay even with the visor open.
9. Using a dull screwdriver, the material needs to be stretched and tucked into the area around the plastic piece that you removed in step 5. I did a little at a time and pushed it into the slit. I kept doing this until I was satisfied that I had it properly stretched and tucked.
10. Cut a hole to re-insert the extender. Make sure that the hole is as small as possible. I had to cut it from the holes where the tabs would go back into to about half way up the hole where the extender was inserted. I left about half an inch of material on each side and just stretched it to make sure that it was tight and the edges were hidden.
11. I used JB Weld to put it back together in two parts. Close up the main piece (everything except the flexible piece that you can see in the picture with Step 2) by putting JB Weld at several spots on the old epoxy lines. I used to pieces of plywood and two C clamps to hold it together. Once you close it up, use a screwdriver to push any fabric back in that is not tight. Take extra time to tuck all the material around the metal piece where it mounts to the ceiling and to the area where it attached to the sun visor bracket. (the plastic rod should not be installed at this point). Let it sit over night.
12. Next repeat the process for the remaininng section but you only need one C clamp.
13. Put the plastic piece that you removed in Step 5 back in place. Push the metal rod through the seam in the material and use a hammer to tap it back in. When it is almost all the way to the material, use a nail set to push it the rest of the way past the material.
1. Use a screwdriver to carefully lift the material piece off the back of the mirrow. It is material wrapped around a thin piece of aluminum that you will want to reuse. The factory only glued the material around the wrapped edge, so it is easy to get off.
2. Cut a new piece of headliner with about a quarter inch of extra all the way around and use adhesive to attach it and wrap the edge. You don't want too much material wrapped around the edge or it won't go on right.
3. I used 5-minute epoxy to reattach it to the back of the mirror cover.
4. Get the remaining piece of the light wires out of the punch through connectors behind the mirror.
5. Cut out large sections of the material in the indentation where the mirror goes back on the sun visor to reduce bulk, but do not cut too close to the edge and don't cut your light wires that you taped in earlier. Use your fingers to gently stretch the material to accommodate the mirror (it is a tight fit).
6. Strip the ends of the light wires and push them back through the connectors.
7. Insert the top of the mirror first and then use a screwdriver to get the tabs at the bottom back into their holes. This is not easy. I thought that I was going to break the mirror, but I managed to get it in without anything broken.
At this point, reinstall your sun visor and this is what it looks like complete. It is a long process, but looks very good when done.