Convertible Top Hydraulic Hose: Service and Repair

Folding Top Cylinder Hydraulic Hose Replacement

Special Tools

BO-47666 - Hose Retainer Ring Installer

Replacement Procedure





Warning: Refer to Eye Protection Warning Eye Protection Warning.


Warning: Refer to Folding Top Hydraulic Pressure Warning Folding Top Hydraulic Pressure Warning.


Warning: Refer to Servicing Electrical Components Warning Servicing Electrical Components Warning.


Caution: Refer to Cylinder Hoses Caution Cylinder Hoses Caution.

1. Place the folding top in the #1 and #5 bow in the up position.

2. Open the rear compartment.

3. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection (LS7 or LS9) Battery Negative Cable Disconnection and ConnectionBattery Negative Cable Disconnection and Connection (LS3) Battery Negative Cable Disconnection and Connection.




4. Locate the hydraulic pump beneath the carpet in the storage compartment on the passenger side of the rear compartment.

5. Turn the hydraulic pump bypass valve (1) counterclockwise until the valve stops.

6. Support the rear compartment lid.

7. Place a protective cover over the rear compartment interior and the adjacent body panels.

8. Remove the side compartment trim carpet. Refer to Rear Compartment Rear Center Trim Panel Carpet Replacement Rear Compartment Rear Center Trim Panel Carpet Replacement.




9. Disconnect the electrical connectors (1) from the folding top control module (2).




10. Remove the nuts from the hydraulic pump bracket.

11. Lift the pump up and out of the storage compartment and set the pump on the protective covering.

Note: If you are replacing hose sets for more than one cylinder, complete the procedure for one cylinder before you begin with another.

12. Remove the hydraulic cylinder from the mounting location. Do NOT remove the hoses from the cylinder at this time.




13. Remove the reservoir filler plug (1).




14. Identify the hose numbers to be replaced.

15. Remove the bolts (1) from the pump manifold plate.




16. Carefully lift up on the manifold plate (1).

17. Locate the pair of cylinder hoses that need replacement. Refer to Folding Top Hydraulic Cylinder Hose Identification Folding Top Hydraulic Cylinder Hose Identification.

Note: Remove the 2 hose connections one at a time. Repeat the following procedure for the second hose.

18. For each set of hoses being replaced, remove one hose by pulling straight up from the pump. Use a clean shop towel to control any hydraulic fluid leakage.

19. Push the hose back through the manifold plate.




20. Remove the hose retaining ring (1).




21. Remove the hose (1) from the manifold plate (2).




22. Push the manifold end of the new hose (1) through the manifold plate (2).




23. Using the BO-47666 - Hose Retainer Ring Installer, install a new hose-retaining ring onto the hoses.

24. Push the assembly cone (2) over the end of the hose (1) until the cone is fully seated.




25. Install the retaining ring (2) onto the assembly cone (1).




26. Using the BO-47666 - Hose Retainer Ring Installer (2), push the retaining ring (1) into place.




27. Remove the assembly cone (1).

28. Repeat the replacement procedure for the second hose.




29. Install a new O-ring (1) on each cylinder hose that you removed from the pump manifold.




30. Align the manifold plate bolt holes to the holes on the pump. This will ensure that the cylinder hoses are placed in the correct port.

31. Align the cylinder hoses into each port and push down until the hoses are seated properly in the hydraulic pump manifold.




32. Install the manifold plate bolts (1). Do NOT tighten.





Caution: Refer to Fastener Caution Fastener Caution.

33. Push down on the manifold plate (1) and verify that all of the cylinder hoses are seated properly.

Tighten the bolts to 10 Nm (89 lb in).

Note: Improper hose routing can lead to hose failure as a result of rubbing or pinching.

34. Route the new hose set to the cylinder in the same way as the set being replaced.

Note: Remove only one fastener at a time so that the amount of slack between fasteners can be exactly duplicated between the hose sets.

35. Depending on the hose set, you may have to remove and replace the following components:

* The tie wraps

* The P-clips

* The wire loom

* The conduit





Note: Remove the 2 hose connections one at a time. You will repeat this entire procedure for the second hose later. Refer to Folding Top Hydraulic Cylinder Hose Identification Folding Top Hydraulic Cylinder Hose Identification.

36. Use a small flat-bladed tool to release the retainer clip (1) from one of the cylinder hoses.




37. Remove the retainer clip (1).





Note: After you have removed the cylinder hose, do NOT move the cylinder rod. This will cause fluid to squirt out of the ports.

38. Remove the cylinder hose (1). Use a clean shop towel to control any hydraulic fluid leakage.





Note: Use caution when removing O-ring from the cylinder. Steel tools can scratch the O-ring sealing surface inside the cylinder which could cause a leak.

39. Remove the cylinder hose O-ring (1) from the cylinder.




40. Install a new O-ring (1) onto the cylinder hose (2).

41. Install the hose into the cylinder port (3). Press straight down on the hose until the hose is fully seated in the cylinder.




42. Install a new cylinder hose retainer clip (1). Inspect the retainer clip to ensure that the clip is fully seated around the hose (2).

43. Repeat the replacement procedure for the second hose.

44. Install the appropriate hydraulic cylinder to the mounting location.




45. Install the reservoir filler plug (1).




46. Position the hydraulic pump to the correct mounting location.

47. Apply LOCTITE(TM) Blue, GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bracket bolts.

Tighten the bolts to 18 Nm (13 lb ft).




48. Connect the electrical connectors (1) to the folding top control module (2).




49. Install the electrical connectors (1) to the hydraulic pump bracket.

50. Install the rear compartment carpet. Refer to Rear Compartment Rear Center Trim Panel Carpet Replacement Rear Compartment Rear Center Trim Panel Carpet Replacement.

51. Remove the protective covering.




52. Turn the pump bypass valve (1) clockwise until the valve stops.

53. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection (LS7 or LS9) Battery Negative Cable Disconnection and ConnectionBattery Negative Cable Disconnection and Connection (LS3) Battery Negative Cable Disconnection and Connection.

54. Remove the rear compartment lid support.

55. Close the rear compartment.

56. Bleed the hydraulic system. Refer to Folding Top Hydraulic System Bleeding Procedures.

57. Inspect the hydraulic system for fluid leaks.

58. Inspect the hydraulic system fluid level and add fluid as needed. Refer to Folding Top Fluid Addition Service and Repair.

59. Inspect the folding top for proper operation. Refer to Power Folding Top Description and Operation Power Folding Top.