manual top

[schoir]

Originally Posted by Canyon Racer

I converted my '02 top to manual operation after one of the cables broke. I disconnected the front bars that connect the canvas top to the transmissions. I replaced the cables and synchronized the transmissions. I now use the button to raise the clamshell then manually raise or lower the top and use the button to lower the clamshell. Just have to lower clamshell before latching the top or the switch doesn't work. I wouldn't change back now that I've lived with it. It's as fast or faster than fully motorized and provides better access to the engine hatch. Before I used the transmission for the clamshell I used a bungee cord but I was less than happy with the need to get out to operate the top. I can put the top up or down while belted in the drivers seat.
Jerry

Jerry:

Excellent workaround and you definitely have the best of both worlds. Once you made the decision that the OEM system was not worth fixing as it was delivered, that sounds to me like the way to go.

There is a hack that will let you operate the clamshell's "hydraulic" pushrods via the transmissions' V-levers, but it involves wiring into the electric motor and bypassing the double relay, IIRC.

Maybe going one step further, if you install an OEM '03 or '04 top and frame assembly as a unit, would yield the most reliable and least expensive to maintain mod, while still being able to remain seated while operating the top (i.e. "NO CHOP" !


Regards, Maurice.

[rock88hard]

Schoir, thank you for such detail in your description, but I'm still lost. I stared at the shop manual and read your post for 20 minutes, while looking at the same pieces of metal seemingly assembled together permanently with some kind of hidden Porsche magic wand. The shop manual showed how to disassemble, but only while the top is completely down but mine is up. And they aren't even making sense to me with their terminology and I certainly don't see any red caps anywhere.

I'm uploading some pics.

Is the nuckle what I disassembled below to expose Area #2? There is what looks like a steel cap in Area #2, but that POS doesn't want to come off and there is no room to get anything between it and it's plastic casing. I will refer to Area #1 in the next pic.



What I think is the pushrod or some kind of bar lays behind Area #1 below. But there is no way to disconnect any of this. Am I completely off and need to look between the seats and doors somewhere?



I want this top completely manual, I'll get speedster bumps or something to secure it, but I no longer want to rely on 5,000 points of failure every time I'm caught at night or in the rain. Please help, I'm not far from taking a razor to it and making it a permanent convertible.

[schoir]

Originally Posted by rock88hard

Schoir, thank you for such detail in your description, but I'm still lost. I stared at the shop manual and read your post for 20 minutes, while looking at the same pieces of metal seemingly assembled together permanently with some kind of hidden Porsche magic wand. The shop manual showed how to disassemble, but only while the top is completely down but mine is up. And they aren't even making sense to me with their terminology and I certainly don't see any red caps anywhere.

I'm uploading some pics.

Is the nuckle what I disassembled below to expose Area #2? There is what looks like a steel cap in Area #2, but that POS doesn't want to come off and there is no room to get anything between it and it's plastic casing. I will refer to Area #1 in the next pic.



What I think is the pushrod or some kind of bar lays behind Area #1 below. But there is no way to disconnect any of this. Am I completely off and need to look between the seats and doors somewhere?



I want this top completely manual, I'll get speedster bumps or something to secure it, but I no longer want to rely on 5,000 points of failure every time I'm caught at night or in the rain. Please help, I'm not far from taking a razor to it and making it a permanent convertible.

Rock:

You are looking in the completely wrong area.

The bolt that you want to remove can be seen if you look straight down into the convertible top well while standing facing where the door meets the rear quarter panel. Look down and just inboard of where the B-pillar is folded down in a horizontal position. The bolt is recessed inside the center of the V-lever.

Go to this link, and take a look at the photo on page 19 of the Part II PDF: installinga'03-'04glasstopandframeona'97 - mikefocke2

(go to the bottom of the page to find the link to the Part II PDF).

That photo will show you the 19mm bolt that you can access while the top is down, but you will need a "small offset" 19mm box end wrench to get it in there. Sears sells one that works well.

Once you remove the 19mm bolt, the V-lever will come off and that will give you access to the both the front and the rear pushrods, whose anchoring locations are
depicted in that photograph.

Regards, Maurice.