Convertible top converted to manual but light won't go off

[djw8282]

Originally Posted by MrBen

Dj could also have a transmission starting to go out. Mine did that for a while before it finally failed. The left side where the switch is located could have a gear problem while the right has enough push to get the top to the point where you can close it. At least with mine it started working erratic jerking and such. It took mine about a year to finally go once the light quit working as it should

Hey Ben,

Interesting stuff. This sounds like my issue because it makes a different noise than what I'm used to on the side of the transmission. It's kind of stuttering slightly to close. Thanks! Is the transmission switch located on or close by?

[78F350]

I think that the change in the design was in the 2000 model and later.
The 2000 and later models have one switch in the latch, a different relay module, and the transmissions are different with the 'B-pillar' microswitch internally rather than on the B-pillar.

Here's a copy from an old post that shows the transmission and microswitch location.

Originally Posted by 78F350

...



...

[djw8282]

Originally Posted by 78F350

I think that the change in the design was in the 2000 model and later.
The 2000 and later models have one switch in the latch, a different relay module, and the transmissions are different with the 'B-pillar' microswitch internally rather than on the B-pillar.

Here's a copy from an old post that shows the transmission and microswitch location.

Awesome..I'm going to look into this later. Thanks!

[MrBen]

That second picture shows the internal switch. The white plastic gear is the one that fails. Mine was literally cracked in half it will still work because it’s packed in there so tight. On mine like I say it was a gradual failure. First the light would not go out. Then it started making noise and jerking a little. Eventually I quit using it for fear of the top getting stuck halfway when I was not home. I took it apart last winter and fixed it. It has worked better than ever since. The write up in the 101 project book has some good photos. I also found a video online. If do decide to take it apart be sure and mark everything with a felt pen so you can get it all back together the same way.

[MrBen]

My car is a 2002 s

[djw8282]

Originally Posted by MrBen

That second picture shows the internal switch. The white plastic gear is the one that fails. Mine was literally cracked in half it will still work because it’s packed in there so tight. On mine like I say it was a gradual failure. First the light would not go out. Then it started making noise and jerking a little. Eventually I quit using it for fear of the top getting stuck halfway when I was not home. I took it apart last winter and fixed it. It has worked better than ever since. The write up in the 101 project book has some good photos. I also found a video online. If do decide to take it apart be sure and mark everything with a felt pen so you can get it all back together the same way.

Well, I have all the symptoms of what you're stating. How did you manage to fix the cracked gear? I'm not sure if I would do a rebuild but I am curious to see the video if you don't mind posting it...I appreciate the help!

[MrBen]

I bought 2 new gears on eBay and replaced both sides. They came in a set. I think you can buy metal gears but I figured Porsche made them plastic as sort of a weak link to start with the videos I found just by googling replacing boxster top transmission or something like that. It’s been a while and I turn 63 tomorrow so I don’t recall details like I once did . It’s not that bad of a job. The 101 project book does a pretty good job of describing how to remove replace and time the transmissions. The video I found was about taking them apart and putting them back together.

[Starter986]

Originally Posted by MrBen

I bought 2 new gears on eBay and replaced both sides. They came in a set. I think you can buy metal gears but I figured Porsche made them plastic as sort of a weak link to start with the videos I found just by googling replacing boxster top transmission or something like that. It’s been a while and I turn 63 tomorrow so I don’t recall details like I once did . It’s not that bad of a job. The 101 project book does a pretty good job of describing how to remove replace and time the transmissions. The video I found was about taking them apart and putting them back together.

Happy Birthday!