Originally Posted by elgyqc (Post 580826)

After I bought my 2000 5-speed just over a month ago I discovered some problems with the roof mechanics. The left side was OK, but on the right side the plastic cup on the forward push rod had broken. Someone removed both the forward and rearward (that lifts the clamshell) push rods and left it so the left side was doing all the work.

I bought a new end cup and started to reinstall everything. I noticed that the 2 forward push rods are not the same shape. I checked the parts catalogue and I see that there is one part number that is supposed to fit both sides. So, I figure that the right side rod got bent after the cup broke and it fell off, but I find no damage in the area where it would have fallen. As well it is not the same length as the left side rod i.e. the sliding adjustment is placed so that the right side rod is longer and there is no indication that the length has been adjusted.

I am going to try to bend the right rod back to the same shape as the left one and adjust it to the same length... but I am having trouble understanding how the roof worked with rods of different lengths and how the rod got seriously bent with no collateral damage. I have already tried to straighten it and it is not easily bent.

The roof seemed to work fine with just the left side connected.



Left side push rod on the bottom, bent right side rod above. The white cup on the lower rod looks funny because I strengthened it by wrapping wire around it and coating it in epoxy.

http://986forum.com/forums/uploads02...1539201588.jpg

Originally Posted by Oldcarguy (Post 580870)

Just a note that the plastic end cups are designed to break if the roof system binds, thereby saving more expensive roof components (usually at the expense of the foam drain tray). For this reason you might want to reconsider using reinforced caps.

Be sure to check the drain trays to make sure they have not been compromised and I’d order two identical rods ensure symmetry.

Originally Posted by elgyqc (Post 580872)

Thanks fellow Oldcarguy, it seems I didn't do my homework on this one. Only after reading your comment did I see a customer review on the site where I bought the metal replacement cup explaining the reason for using plastic. I have ordered a set of plastic cups. My repair philosophy is to do as much as I can myself and reuse the maximum of old parts, so I was able to reform the bent pushrod. That's me not a reflection on others who prefer shiny new parts at all times. For example, against all advice, instead of buying a rebuilt unit I resealed the steering rack on my 928. No leaks yet so I am happy with that decision... so far.
I did repair the the right side drain tray, it had a hole in it that I assume happened when the end cup broke. The reason I started investigating the roof was that I was getting water on the floor behind the passenger seat.

Originally Posted by KT986 (Post 580829)

Trick is to have the motors in sync.
Once you have the roof has a tolerance , maybe 0.5 mm to 1.5 mm on either side relative to each other . That's where they need adjustment - it's quite possible the arms are of different lengths ( slightly) from factory .
Hence you can't see the " adjustment ".
Critically, both sides have to be symmetrical

Hope that helps

KT

Originally Posted by Brian in Tucson (Post 580974)

You have one bent rod (the upper one in the pic.) You can straighten it with a hammer and a acetylene torch. I probably wouldn't, I'd be looking for one rod on Ebay. Then when you put it all back together with new cups, make sure each rod is exactly the same length from where it connects to the transmission to where it connects on the top. Both sides should be identical & interchangeable, same exact length for both. And synchronize the transmissions, you can turn the right transmission with an electric drill connected to the cable where it attaches to motor. Pelican's writeup about rebuilding the transmissions is pretty good and goes into all this stuff.

I will suggest this, when they go wrong, they can be a major pain in the butt to get back to correct. Mine had bent rods, at least one clamshell carrier, and a stripped gear in the right transmission. Still trying to get it so that it doesn't bind or pop. And trying to get the clamshell to close flat on the right side.

I feel your pain, good luck bro!