986 roof stuck open.

[mikehkang]

Hello MN 986 and Maurice,

Thank you for your answers.
You guys gave me the courage to take the car apart!

I have confirmed that the driver side cable is bad. The protruding portion that connects to the motor is broken.

The cable is on its way.

I have a few more questions if you guys don't mind.

- The 19mm bolt that holds the v-lever to the transmission is REALLY stuck. It looks like loctite was used to keep the bolt from coming off.
Q1-3. Does Porsche use loctite at this location? Regardless, should I use loctite when I put it back? I also don't have a torque wrench. Do I need one for this job?

Q4-6. Is there a switch near the motor? I couldn't see one. Otherwise, how does the car know that the top is completely folded and the clamshell closed so to stop the motor? Is it possible that the heavy rain from the days before fried the switch?

Thank you both guys again for the prompt help.

[schoir]

Originally Posted by mikehkang

Hello MN 986 and Maurice,

Thank you for your answers.
You guys gave me the courage to take the car apart!

I have confirmed that the driver side cable is bad. The protruding portion that connects to the motor is broken.

The cable is on its way.

I have a few more questions if you guys don't mind.

- The 19mm bolt that holds the v-lever to the transmission is REALLY stuck. It looks like loctite was used to keep the bolt from coming off.
Q1-3. Does Porsche use loctite at this location? Regardless, should I use loctite when I put it back? I also don't have a torque wrench. Do I need one for this job?

Q4-6. Is there a switch near the motor? I couldn't see one. Otherwise, how does the car know that the top is completely folded and the clamshell closed so to stop the motor? Is it possible that the heavy rain from the days before fried the switch?

Thank you both guys again for the prompt help.

Mike:

Kudos for trying to tackle it. You should be able to do this repair without too much trouble.

The 19mm bolt that holds the v-lever to the transmission is REALLY stuck. It looks like loctite was used to keep the bolt from coming off.
Q1-3. Does Porsche use loctite at this location? Regardless, should I use loctite when I put it back?

Porsche does use loctite on that 19mm bolt, and you should use it as well. That V-lever is under a LOT of pressure at certain points of its travel. You can use blue Loctite and it will be fine. (From the write-up on Mike Focke's Website: Coat the ends of the threads on the 19mm bolt with Loctite Blue, install and tighten the bolt to 59 ft/lbs) This, and further instructions are found on the Part II PDF, at page 30, paragraph 22 of the DIY, here: http://sites.google.com/site/mikefocke2/installinga'03-'04glasstopandframeona'97

Q4-6. Is there a switch near the motor? I couldn't see one. Otherwise, how does the car know that the top is completely folded and the clamshell closed so to stop the motor? Is it possible that the heavy rain from the days before fried the switch?

The only switch near the motor (only on 97 to 99 Boxsters), is the black lever microswitch which is located and mounted directly on top of the electric motor.

That black lever microswitch is how the car "knows" that the clamshell is closed, as that switch sends a signal to the convertible top double relay, which then initiates an "after-running time" of fractions of a second...which then cuts power to the motor and turns off the "top open" idiot light on the dash.

Heavy rain usually does not affect that switch or the motor...However, check under and behind your driver's seat to verify that the rain water has not found its way to the central alarm computer under that seat.

Regards, Maurice.

[mikehkang]

Gentlemen,

I am here to report to you that the top is up, a pun(?), and running again. :dance:
Thanks to Maurice and MN 986 and the other silent well wishers, I have completed my first significant repair.

I do have one more question regarding the clamshell.
During the PPI back in Dec 2009, it was noted that the pointed part of the clamshell, the driver side, was misaligned - the pointed part used to go down about 1/2 inch more than it should when the top was fully opened or closed.

As a by product of the repair, the alignment is much better but still not perfect.
Is there a way to adjust the fit/alignment as this pointed parted of the clamshell when the top is fully opened or closed?

Again thank you everyone for help.

Michael

[schoir]

[QUOTE=mikehkang]Gentlemen,

.....
I do have one more question regarding the clamshell.
During the PPI back in Dec 2009, it was noted that the pointed part of the clamshell, the driver side, was misaligned - the pointed part used to go down about 1/2 inch more than it should when the top was fully opened or closed.

As a by product of the repair, the alignment is much better but still not perfect.
Is there a way to adjust the fit/alignment as this pointed parted of the clamshell when the top is fully opened or closed?
....

Michael:

Great work, and way to jump in there!

The height at which the tips of the clamshell sits when completely open or closed can be adjusted.

Put the clamshell in the rearmost (45 degrees) position and take a look at the area against and just outboard of the large gasket that surrounds the convertible top well, just aft of where the rear of the door meets the quarter panel.

You should see a small, rectangular black plastic part that sits there and that has a small wing that tucks under the gasket so as to remain put. That black plastic contraption consists of two parts sandwiched on each other. Pulling the two apart lowers the level at which that tip of the clamshell ends up, pushing the two together raises that tip of the clamshell.

In your case, since it's the driver's side that ends up a little lower than it should, first check to make sure that the little part is actually there. Then, check the passenger's side for comparison and you should then be able to make the adjustment.

Not a great photo (only one I could find now), but here's what it looks like at the bottom edge of the photo, near the right corner:



There is one more adjusting mechanism that affects the level at which the clamshell sits, but try this one first and let us know how it works out.

Keep up the good work!

Regards, Maurice.

[mikehkang]

Hello Maurice,

Have I circled the correct part?
I don't have that part. There is nothing but rubber there, no plastic, in my car.

It is not that bad now. That is, compare to how it was BEFORE, it looks fine I guess.

What is the another method of adjustment?

Thank you.

Michael

[schoir]

Originally Posted by mikehkang

Hello Maurice,

Have I circled the correct part?
I don't have that part. There is nothing but rubber there, no plastic, in my car.

It is not that bad now. That is, compare to how it was BEFORE, it looks fine I guess.

What is the another method of adjustment?

Thank you.

Michael

Mike:

You have circled the correct part.

Do you have one on the other side?

The other method of adjustment acts more on the overall level of the clamshell, and it's done by means of an eccentric screw which is located at the bottom end of the body-colored aluminum (magnesium?) clamshell arm. There is a 10mm nut with a threaded screw that has a slot in the middle of it that must be loosened before the eccentric can be moved in its non-concentric circle of travel. That has the effect of raising/lowering the plane of the clamshell on that side.

If you do play with that adjustment, MAKE SURE that you mark your starting point so that you don't make it any worse. It's a little tricky.

The correct part that you have circled should be there for proper alignment of the tip of the clamshell. You should get a replacement as it's not an expensive part.

Regards, Maurice.

[mikehkang]

Hello Maurice,

No, it is missing from both sides.
I will look for the part number.

Thank you,