Convertible Top - Multiple Noises
Boxster1/00
6101
Binder - 6, Body Ext. Equipment
Noises In The Convertible Top
Vehicle Type:
Boxster/Boxster S
Model Year:
As of 1997 (V)/2000 (Y)
Concern:
Noises in the convertible top/convertible-top compartment lid.
Information:
The following information contains the most up to date specifications for repairing complaints of noises in the convertible top and the convertible-top compartment lid. Before beginning the work, please road test the vehicle to isolate the area where the noise is coming from. Then refer to the technical bulletin for assistance After completing work road test the vehicle again to confirm the noise was eliminated.
Parts Information
Work Procedure:
Setting up the convertible top to perform repairs. The tension bow seal; can be damaged or destroyed if the following procedure is not followed correctly.
1. Unlock the convertible top at the windscreen frame.
2. Move the convertible top rearward by means of the electric motor until the convertible-top compartment lid has reached its rear end position.
3. Move the convertible top forward by means of the electric motor until the convertible-top compartment lid just moves forward, and then stop it.
4. Disengage the cloth covering at the rear and the tension cables on the left and right sides.
5. Fold the tension bow upward toward the main bow until it engages.
6. Remove the ignition key from the ignition lock.
Note:
The convertible top must no longer be electrically operated in this position.
CAUTION
Danger of injury by the convertible-top mechanism.
> The convertible-top rocker switch must not be actuated while working on the convertible top.
> Remove the ignition key before starting work on the convertible top.
Complaint 1:
Creaking and squeaking noises from the area where the windscreen frame meets the roof frame/convertible top lock.
Cause:
Metal retaining strip at the front of the convertible top not flocked (a felt like covering that is applied during the manufacturing process of the retaining strip). Movement between the windshield frame seal and the retaining strip (A in figure 2) on the roof frame (D in figure 2).
Repair:
Open the top half way. On vehicles (without a flocked retaining strip, cover the area that contacts the windshield frame seal with a piece of Teflon tape. Cut a strip of tape 20 x 1190 mm and place as shown in figure 2 arrows.
Notes:
Make sure the retaining strip is clean from grease before applying the tape. The flocked retaining strip was installed as of model year 2000.
Complaint 2:
Rattling from the outer windshield area at the top and the roof frame on the left or right hand side.
Cause:
Movement between the convertible top and windscreen frame combined with play of the convertible-top support (figure 6, item B) in their mounts in the windshield frame.
Repair:
Open the top half way. Check whether the caps on the support have three ribs on the underside (figure 3, item C arrow). If necessary, replace the caps with caps with out ribs.
Installing a new cap.
1. Using a suitable pair of pliers, pull the caps off the support.
2. Clean the support ends.
3. Apply the instant glue to the end of the support.
4. Fit the cap on the support and drive it home with a plastic hammer.
Adjusting the fit into the windshield.
1. Loosen the two T30 screws at each of the mounts (figure 4, arrow a).
2. Move the mounts forward, towards the passenger compartment (figure 4, arrow b).
3. Pull the roof frame seal from under the mounts and lay it over the mounts (figure 5, arrow).
4. Tighten and torque the Torx bolts to 7 nm (5.0 ft lb.).
5. Close the convertible top and check the absence of play by vertically shaking the roof frame with the doors open. If play is still present, apply a felt strip of 25 x 20 mm to the top of each support (figure 6, arrow).
Complaint 3:
Rattling from front area of roof frame on the left or right hand side.
Cause:
The handgrips, which are integrated in the roof frame to aid in closing, can become detached and cause a rattling noise. The noise can be heard by striking the roof frame (figure 7, arrows).
Repair:
Remove the grips by inserting a plastic spatula between the grip and the roof frame on the side opposite to the sun visor stop. Carefully lever out the grip. Apply instant glue on the contact surface of the grip where it contacts the roof frame and then reinstall it back in the roof frame.
Complaint 4:
Squeaking from the area of the seal on the roof frame above the door window on the left or right side.
Cause:
Movement between the bottom of the seal on the side of the roof frame and the retaining strip.
Repair:
Open the top half way. Disengage the seal (figure 8, item D) from the
retaining strip. Treat the bottom of the seal with Kytrox or Sicilian lubricant. Press the seal back into the retaining strip.
Complaint 5:
Creaking from area of the B-pillar on the left or right hand side.
Cause:
The clamp touches the B-pillar and the clamping rail touches the main bow with the convertible top closed. Movement of these parts against each other causes creaking noises.
Repair:
Replace the Teflon tape on the clamping rail with felt tape.
1. Open the edge of the convertible top until the front edge is positioned above the rollover bar.
2. Remove the T20 Torx screw which secures the tension cable to the end of the main bow (figure 9, arrow a).
3. Pull the convertible top covering away to gain access to the clamping rail on the main bow.
4. Remove the Teflon tape from the forward facing notch of the clamping rail. Clean off any remaining residue from the notch (figure 9, arrow b).
5. Cut a piece of felt tape to 25 x 30 mm and stick it around the notch of the clamping rail (figure 9, arrow c).
6. Reinstall the cable and close the top.
Complaint 6:
Rattling from the area of the B-pillar on the left or right hand side.
Cause:
The main control arm (also called the push bar of the roof frame - figure 10, item H) touches the screw of the clamp (figure 10, item F) when the top is closed. Rubbing marks on the main control arm or impressions on the Teflon tape that is wrapped in this area indicates this condition.
Repair:
Complaint 7:
Knocking or creaking from the area of the B-pillar on the left or right hand side.
Cause:
The main bow touches the hardtop mount (figures 11 and 12 arrows) when the convertible top is closed. Movement between them causes knocking or cracking noises.
Repair:
1. Open the convertible top almost completely to allow access to the hard top-mounting bracket (arrow in figure 13).
2. Using a straight grinder (figure 12) with a cylindrical grinding bit, grind away a recess in the hard top bracket approx. 2 mm deep x 10 mm wide (arrow in figure 14). Make sure to vacuum up any metal chips deposited in the vehicle.
NOTE:
A modified hardtop mount was installed in production as of 6-2-1999.
Complaint 8:
Rattling from the rear convertible-top area below the rear window on the left or right hand side.
Cause:
The brackets (Item b, figure 15) that are riveted to the underside of the tension bow (item a, figure 15), which the tensioning cables attach to, are loose. The rivets, which secure the brackets, become loose due to the force exerted by the tensioning cables.
Repair:
Move the convertible top to the service position. Drive a 10 mm washer or a sheet metal blank (approx. 10 x 10 mm) between the bracket and the bow (item c, figure 15). A washer with a necessary thickness must be selected so that when it is installed, there is no longer any movement of the bracket.
Complaint 9:
Grating from lateral area of the tension bow on the left or right hand side.
Cause:
The ball sockets of the tension cables are rubbing on the ball heads of the tension bow and adjusting piece.
Repair:
Move the convertible top to the service position and detach the tension cables at both ends. Apply a thin coat of grease on the ball heads (figure 16) then reinstall the cables.
Complaint 10:
Rattling from the convertible top rest on the left or right hand side.
Cause:
The tension cable adjuster is part of the lower fastening point for the tension cables. The adjusters are located on the right and left hand side in the convertible top rest (figure 17). A bracket (item b, figure 18) with a ball head (item c, figure 18) is inserted in a fixed guide segment (item a, figure 18). The hexagon head bolt (item d, figure 18) adjusts this bracket. Play can develop between the bracket and the guide segment.
Repair:
Eliminate the play in the bracket.
1. Move the convertible top to the service position.
2. Unclip the cover trim from the guide arm of the convertible-top compartment lid.
3. Fold the water collection tray back out of the way by first removing the two rear plastic screws. Then detach it from the adjusting screw and the ball head of the adjusting piece. Pull the lining aside until the adjusting piece becomes accessible.
4. Press the guide segment together at the lateral flanges (item a, figure 19) until there is no longer any play between it and the bracket.
5. Using the flat end of a pry bar or a tire iron, place it against the flange (figure 19) and strike it with a hammer.
6. Check to see if there is any play by shaking the ball head firmly.
7. 3GReinstall the lining, making sure it is positioned under the seal.
Complaint 11:
Fluttering noise from the area of the tension bow.
Cause:
The convertible top flutters when the vehicle is in motion. The convertible top material strikes the tension bow at the lower edge of the rear window.
Repair:
1. Using the procedure outlined in the Boxster Technical Manual (Group 6, page 61-11), detach the convertible-top covering from the tension bow.
2. Remove the felt strip on the top of the tension bow. This can be accomplished by soaking the felt with solvent (naphtha) for 10 minutes. Remove any remaining residues from the bow.
3. Cut a piece of sponge rubber tape to a size of 25 x 1, 139 mm and stick it on the tension bow (arrow, figure 20).
4. Reinstall the convertible-top covering on the tension bow again.
Complaint 12:
Grating of rattling noises from the lateral convertible-top rest on the left or right hand side.
Cause:
The guide arm of the convertible-top compartment lid (arrow a, figure 21) can touch the push bar to the main bow (arrow b, figure 21) when the convertible top is closed. See arrows in figures 21 and 22 for contact points.
Repair:
Adjust the convertible top compartment lid (see complaint 13.2). After completing the ad justment, check whether the guide arm of the convertible top compartment lid (arrow a, figure 21) touches the push bar (arrow b, figure 21). Both sides should clear. If it doesn't, proceed as follows.
1. Move the convertible top to the service position.
2. Disengage the tension cables and clothe covering and fold the tension bar up against the window.
3. Close the convertible top compartment lid. To do so, hold the convertible top switch in the close position until the lid is completely closed.
Caution!
Be careful not to trap any parts when closing the lid.
4. The location or contact point (arrow X, figure 21) of the guide arm and push bar is visible on this position. If the guide arm is touching the push bar, mark the contact point on the guide arm (arrow X, figure 21).
5. Open the convertible top compartment lid by means of the electric motor and grind off approximately 5 mm of material on the marked location on the guide arm (arrow Xa, figure 22).
6. Repeat steps 3 to 5 until the clearance is achieved.
7. Vacuum up metal chops and reinstall removed parts.
Complaint 13.1:
Rattling from the rear area on the left or right hand side.
Cause:
The sliding piece (left or right-item a, figure 23) for the guide arm (item b, figure 23) of the convertible top compartment lid is loose in the guide rail (item c, figure 23). This can result in rattling noises when the vehicle is driven. This play can be checked by shaking on the guide arm (item b, figure 23) with the convertible top compartment lid open.
Note:
High temperatures, such as those produced when the vehicle paint work is bake (dried), can reduce the spring force of the sliding piece.
Repair:
Replace the guide piece on the left and/or right hand side.
1. Move the convertible top to the service position.
2. Unclip the cover trim from the guide arm of the convertible top compartment lid.
3. Remove the M6 collar nut (item d, figure 23) and pull the guide arm (item b figure 23) off the eccentric bolt (item e, figure 23).
4. Unscrew the rear combination screw (item f, figure 23) on the guide rail.
5. Pull the sliding piece out of the guide rail to the rear.
6. Unclip the eccentric bolt from the old sliding piece and clip it into the new one.
7. Insert the sliding piece into the guide rail. Fasten the guide with the combination screw.
8. Push the guide arm onto the eccentric bolt and fasten it with the M6 collar nut.
9. Close the convertible top and check the adjustment of the convertible top compartment lid. If necessary, adjust the lid for proper fit. See complaint 13.2. When finished, clip on the trim that attaches to the guide arm.
Note:
The part number for the left or right side sliding piece is 986 561 577 01.
Complaint 13.2
Rattling from the rear area.
Cause:
The convertible top compartment lid is not resting properly on the front stops on the left or right hand side. The stops are damaged or set too low.
Repair:
Check the stops in the water channel on the left and right sides for signs of damage. Open the convertible top compartment lid to its rear most position. The stops are now visible and can be inspected. Replace the stops if the are damaged (top part missing or loose).
Adjusting the convertible top compartment lid.
1. With the convertible-top compartment lid open, move top part of the stops in the water channel (arrow, figure 25) rearward to the "low position on the left right hand sides. Unclip cover trim from the guide arms of the convertible-top compartment lid.
2. Fully open the convertible top by holding the convertible-top switch in "open" position.
3. Undo M6 collar nut (10 mm) on the respective eccentric bolt (arrow, figure 26). Turn the eccentric bolt with a screwdriver in order to lift the guide arm to the highest position in the area of the eccentric bolt.
4. Check the position of the front tips of the convertible-top compartment. Adjust the position of the tips by turning back the eccentric bolt until the tips are approx. 1 mm lower than the cover on the mount for the Roof Transport System (left/right).
5. Tighten M6 collar nut on both sides (arrow, Figure 26), holding the eccentric bolt in position with a screwdriver.
6. Open convertible top compartment lid.
7. Move top part of the stops in the water channel forward to "high" position on both sides until the top part covers the bottom part.
8. Fully open the convertible top. Check position of the front tips of the convertible-top compartment lid.
9. When the convertible-top compartment lid is closed, its front tips (arrow a, figure 27) must be at the same level as the cover on the mount for the Roof Transport System (arrow b, figure 27).
10. In order to check the adjustment, open and close the convertible-top compartment lid several times. If necessary, correct the adjustment by shifting the top part at the lateral stop with the convertible-top compartment lid open.
Important:
The convertible-top compartment lid must rest on the lateral stops under slight pressure when closed, otherwise rattling noises can occur.
Complaint 13.3
Rattling from the rear area.
Cause:
In many cases, the rear lid (luggage compartment) is the cause for rattling noises. The lid moves in the lock due to incorrectly adjusted stops.
Repair:
Check adjustment of the stops in the lid. The rattling noise can also be produced with the vehicle stationary by briefly pressing on the rear edge of the lid (arrow a, figure 28) several times.
Caution!
Exerting too much pressure on the rear lid will deform it. The stops in the lid (arrow b, figure 28) must be gradually and evenly unscrewed at the left and right sides until the rattling noise can no longer be produced.
Working Time:
Literature:
Boxster Technical Manual, Groups 5 and 6:
55 90 37 - Disassembling and assembling rear lid.
61... - Convertible top.
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