Crack goes the top

[RandallNeighbour]

http://www.renntech.org/forums/lofiversion/index.php/t68.html

Found this link on renntech to a good thread on the reason older boxsters (97-99)have top problems.

In a nutshell, there's a plastic covered cable that links the top's raising/lowering mechanism to the transmission on each side. This cable stretches in length due to heat.

When it stretches, the metal cable within it that turns (as opposed to pushing or pulling) become disengaged (it does not stretch like the plastic). When this happens, one side goes up and the other doesn't and the clamshell twists and you say "oh crap."

The dealers do not remove the cables and shorten them to insure the metal inside bit is 3/4 out the end as it should ... they replace the whole transmission assembly for both sides at a whopping expense.

So, according to Jeff's thorough posts on Renntech (aka ToolPants) with pictures, he recommends that concerned boxster owners do the following:

1. Check to see if you have the newer cables, which have some sort of diamond pattern on them. These new cables are reinforced and should not stretch or grow. You're fine.

2. If you have the old ones, you have two options. Replace them with the new reinforced ones or remove them and shorten the plastic covering, exposing the 3/4 inches required for trouble free operation. Parts numbers and pictures are available on the thread above.

I still want to know if I can unscrew a couple of bolts somewhere and raise my top manually along my trip if it becomes messed up... there's gotta be a procedure for this... I just need to learn how to do it before the big trip just in case.

[Tool Pants]

That link is almost 2 years old and I almost forgot about it. I have just added to it how I recently fixed the original cables on my car.

The cost is nothing but your time. All 1997-1999 cars with the original unreinforced cable will have a problem sooner or later. Then you get the $1,500-$2,000 repair estimate.

For rbs the new style top transmissions list at about $450 each. Just for those 2 parts. You are calling them motors by mistake.

We use the original top tansmissions and fix or replace the cables. That cost 0 - 60 dollars if you have not already broken other parts.

[RandallNeighbour]

Jeff, can the top be freed up if it seizes due to a broken whatever and manually raised in an emergency?

If so, how does one go about that?

[rbsboxster]

thanks, Tool Pants.

so how do i know if the dealer actually replaced the two transmissions or just the cable? I am from NY so i am always paranoid.

[Tool Pants]

Shortly after renntech.org started I had a section just for top issues created. So Boxster owners could research in just one place rather than all over the internet and on various boards. Just to see the same question having been asked 100 times in 100 different places. Just like a 2 year old thread on renntech has come back to life with additional information and pictures.

I seldom answer top problem questions on other message boards but direct people to the top section of renntech for these reasons.

For rbs, what are the part numbers on your repair invoice.

[RandallNeighbour]

Well then, I will search the renntech threads on the top to see if it can be brought down manually. So keep me guessing... it's good for me I guess.

Good news on my top.

The cables appear to be the reinforced kind with the criss-cross reinforcement seen bulging out a bit from under the plastic tubing covering them.

The push rod assemblies have WHITE ball ends... which means they're the newer ones released last year and not the red ones that were original to the car.

I think I've determined what's causing that intermittent cracking sound as the top comes down. The nut that holds the white ball joint in place on the push rod is fell off.

:dance: :dance:

Just went out to take some pictures of the upgraded cable for you guys to see and there she was... the nut was lying right there on the rubber mat! I just have to run to the store to get some lock tight stuff to goop on the threads before I tighten it.

This really eases my mind... I was freaked out I would be somewhere in Nevada on my trip and the top get all torqued up and the clamshell bent and no dealership in sight... or I get it to a dealership and they want to charge me $$$.

BTW, my mechanic, who works at a dealership during the day, says they replace the upgraded, reinforced cables all the time without doing the transmissions. So, if you have the originals on your 97-99 boxster, it can be done at the dealership if you are not handy.

If you haven't had a good look at the top raising and lowering mechanism on your boxster, it's a good thing to learn about. It's actually quite ingenius, and learning about it and seeing if those nuts are on there will ease your mind as well.

[rbsboxster]

part numbers were:

986-561-180-03

and

986-561-179-03

they are listed as folding top transmission

[Tool Pants]

Those are the new style top transmissions used on 2000 up. Because your original transmissions were replaced that is why your repair was expensive.