Body - Convertible Top Flapping at 75MPH
Boxster (986)4/04 6113
Date: 1-27-05
Binder - 6, Body Equipment
Convertible Top Covering Noises (Flapping) Starting At Approx. 75 mph (120 km/h)
Vehicle Type:
Boxster (986)/Boxster S (986)
Model Year:
2003 (3) - 04 (4)
Concerns:
Convertible top covering flapping noise starting at approx. 75 mph (120 km/h).
Information:
The cause is the convertible top covering beating on the roof frame due to air turbulence caused by vehicles driving ahead of the Boxster. In the event of a complaint, a plastic foam mat needs to be installed between convertible top covering and roof frame.
Parts Information:
Materials:
Only if necessary - Commercially available double-sided adhesive tape, e.g. Tesa (No. 04965-0017-900), for fastening convertible top covering on front roof frame.
Tools:
Scissors
Clean cloth
Cleaning agents (solvent naphtha, spirit, etc.)
Felt-tip marker (ball-point pen, if necessary)
Work Procedure:
Retrofit a plastic foam mat between convertible top covering and roof frame.
The convertible top covering is detached up to the rear mounting on the roof frame and the plastic foam mat is fastened to the roof frame with a Velcro strip.
1. Open convertible top half way.
2. Detach convertible top covering up to rear mount on roof frame and fold backwards (Figure 1), see POSES, Workshop Manual, Group 6, 61 28 55 - Replacing convertible top covering.
3. Work on the Velcro strip.
3.1 Cut the Velcro strip included in the parts kit into two different lengths:
Part 1: approx. 94 cm (> rear roof frame),
Part 2: approx. 100 cm (> front roof frame).
4. Work on front of roof frame
4.1 Clean roof frame in the area where the Velcro strip is supposed to be applied (Figure 2).
4.2 Partially pull off adhesive protective film on the Velcro strip (I = approx. 100 cm).
4.3 Bond Velcro strip on the roof frame, beginning at the roof frame projection (Figure 2, arrow), approx. 0.5 cm parallel to the edge of the roof frame.
5. Work on rear of roof frame (felt covered cover molding).
5.1 Partially pull off adhesive protective film on the Velcro strip (I = approx. 94 cm).
Caution!
Insufficient bonding force of Velcro strip on the felt covered cover molding if the Velcro strip is pulled off and pressed on again in order to correct its position after it has been installed.
> Bond Velcro strip along the rear edge of the felt (Figure 3, arrow).
> Do not correct the position of the Velcro strip after it has been installed.
6. Fasten trapezoidal plastic foam mat.
6.1 Rear of roof frame (felt covered cover molding).
Caution!
Insufficient bonding force of Velcro strip on the felt covered cover molding if the Velcro strip is pulled off and pressed on again in order to correct its position after it has been installed.
> Position the trapezoidal plastic foam mat centered (in direction of travel) with the light side facing up and align to roof frame.
> Arrangement of plastic foam mat in direction of travel: wide side of trapeze to the front, narrow side to the rear.
> Position plastic foam mat along the rear edge of the Velcro strip (Figure 4, arrows).
> Press the plastic foam mat onto the Velcro strip after inspecting it visually and correcting its position.
6.2 Tighten the plastic foam mat uniformly and free of wrinkles on the front of the roof frame by pulling slightly toward forwards, and press on the Velcro strip.
7. Remove the previous side convertible top seals (Figure 5, Items A, B, and C; figure shows the right side of vehicle) and replace by the seals contained in the parts kit.
8. Work on roof frame seal in corner area (right and left) (Figure 6).
8.1 Mark the contour of the foam seal (Figure 6, with Item D marked) on the roof frame seal with a felt-tip marker or ball-point pen.
8.2 Remove any remaining foam seal.
8.3 Cut the seal contained in the parts kit (30 x 1 x 0.5 cm) into two pieces, each 15 cm long.
8.5 Pull off the adhesive protective film from the new seal and bond the seal to the roof frame seal as drawn.
8.5 Remove seal (Item E).
8.6 Cut the seal contained in the parts kit (12 x 1 x 0.2 cm) into 4 pieces, each 3 cm long.
8.7 Put 2 seal parts on top of each other and fit on the roof frame seal (Item E).
9. Work on front roof frame plastic foam mat (Fig. 7).
9.1 Trim the plastic foam mat projecting over the front roof frame. To do this, fold the plastic foam mat and mark the line of the roof frame edge in the fold with a felt4ip marker (Figure 7).
9.2 Cut off the plastic foam mat with scissors approx. 1 cm from and parallel to the line.
10. Install convertible top covering, see POSES, Workshop Manual, Group 6, 61 28 55 - Replacing convertible top covering.
Note:
If necessary, supplement the bond for mounting the convertible top covering on the front roof frame with commercially available adhesive tape.
Working Time:
References:
POSES, Boxster (986) Workshop Manual:
> Group 6: 61 28 55 - Replacing convertible top covering
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