Body - Convertible Top Creaks/Pops or Rattles
03-023October 9, 2006
*Applies To:
2000-07 S2000 - ALL*
Convertible Top Creaks, Pops, or Rattles While Driving Over Rough Roads (Supersedes 03-023, dated April 1, 2003, to update the information marked by the black bars and asterisks)
SYMPTOM
The convertible top creaks, pops, or rattles while driving over rough roads. This noise is only noticeable with the top raised and the driver's and passengers windows closed.
PROBABLE CAUSE
This noise can be the result of any of these causes:
^ Gaps between the mounting bracket and the plastic trim of the convertible top lock handles
^ Various weatherstrip pieces and plastic parts are rubbing on the convertible top frame
^ Dry pivot points on the convertible top frame
CORRECTIVE ACTION
Add EPT sealer to the lock handles, and lubricate the indicated areas.
REQUIRED MATERIALS
Shin-Etsu Silicone Grease:
P/N 08798-9013, H/C 4642294
(One tube repairs about 25 vehicles.)
White Lithium Grease:
P/N 08732-0005, H/C 2963718
(One can repairs about 25 vehicles.)
NOTE:
Make sure you use white lithium grease in the aerosol can. It has special solvents that allow deep penetration into small areas of the joint to effectively dampen any noise caused by movement. It also sets up quickly to form a thick coating as the carrier gas evaporates. Other grease or application methods do not work as well.
EPT Sealer (3T):
P/N 06990-5A5-000, H/C 2086643
(One roll repairs about 100 vehicles.)
WARRANTY CLAIM INFORMATION
*In warranty:
The normal warranty applies.*
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
DIAGNOSIS
Raise the convertible top, and close all the windows. While an assistant test-drives the vehicle to duplicate the noise, pass a stethoscope (with the probe removed) over the area of the convertible top lock handles and along the side of the convertible top frame to pinpoint where the noise is coming from. Go to the REPAIR PROCEDURE, and do all the steps to eliminate the noise.
NOTE:
This repair procedure fixes the most common causes for this convertible top noise. Using the stethoscope helps in the diagnosis to make sure there are not other sources that need to be looked at.
REPAIR PROCEDURE
1. Cut eight 10 mm x 10 mm pieces of EPT sealer (31).
2. Remove the adhesive backing from each piece, then fold each piece over on itself to form a 10 mm x 5 mm wad.
3. Remove the lock handle (two screws), and turn it over.
4. Use a small pocket screwdriver to stuff four wads of EPI sealer between the plastic trim and the mounting bracket of the lock handle as shown.
5. Reinstall the lock handle.
6. Repeat steps 3 thru 5 for the other lock handle.
7. Apply a dab of Shin-Etsu silicone grease to the A-pillar header weatherstrip. Use your finger to rub the grease thoroughly into the weatherstrip material.
8. Apply a dab of silicone grease to each of the door glass weatherstrips (six total) on the convertible top. Use your finger to rub the grease thoroughly into the weatherstrip material.
9. Apply a dab of silicone grease to the hook, locating pin, and rubber cushion of each lock handle.
10. Open the convertible top halfway, and apply a dab of silicone grease to the hard plastic caps on the ends of the convertible top frame and to the ends of the door glass weatherstrips.
11. Use a shop towel to cover the back side of each convertible top frame pivot point.
12. Spray white lithium grease onto each of the pivot points.
13. Test-drive the vehicle to make sure the noise is gone.
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