How to install the whole top mechanism from zero.
 

Hey guys,

I got a Boxster with maually operated top. I just bought all parts to get it back to motor-driven mode. Does anyone know how to do that?

I already figured out how to link each part. But I am wondering how to align the clam shell and the top. I have a few alignment question.
1. How to align the gear on two sides?
2. How to align the clam shell with the top?
3. How to align the clam shell when it is in service mode(open)?

Thanks!

That sounds like a lot of work that I have not tried. Pelican Parts has several top articles in the Body / Interior / Exterior section half way down this page. Perhaps you can glean some help from those. I do know that getting them sync'd correctly is very important. Best of luck.

https://www.pelicanparts.com/boxster/boxster_tech.htm

The '97 - '99 have some minor differences from the later ones in how the transmissions are set-up. Just keep that in mind as you look through the guides if it isn't making sense with how yours looks..
Mike Focke's Boxster pages have good info to supplement what is in the Pelican Parts articles: https://sites.google.com/site/mikefocke2/thetop-itsmaintaince%26replacement

The Bentley Service Manual also has good information as to how to get everything lined up. If you don't already have one I highly recommend picking one up.

On my 02 the transmission had alignment marks stamped in from the factory. I hooked up a drill to the cable like in the 101 book. I set them up exactly the same. It is so smooth now I imagine it's like showroom.

Here's some info that should help you from the Bentley manual.


Align the lever by arrow marks on the cover.
Torque spec for lever to transmission is 59 ft-lb.
Torque spec Transmission to side panel is 16 ft-lb.

Convertible top link in closed position should be 7.68 inches. To do this you measure the distance from link pivot at drive lever to top of the convertible casket.

Here's a video I found to install for 99 and a video on how to remove it. This video starts after the clamshell and the gear has been installed.

https://www.youtube.com/watch?v=PlX_woJLJGE https://www.youtube.com/watch?v=mkTLoHlhGPY

Thanks. I already have the roof on. What should be the position of the roof (folded or half-opened) when I finished the linkage of the clamshell?

Could you please let me know where do you get the number 7.68 inches. The Bentley manual? But why? Thanks.