Andre Kristian

Hi msand9898, Sorry I didn't see your reply. For whatever weird reason the notification email from renntech.org were automatically filtered by gmail and went to the "Promotions" (which I hardly open) instead of directly to inbox. Just happened to see it when I tried to clean up my mailbox. Anyway, that looks pretty serious break. Something mechanically (I suspect the clamshell) must blocking the movement of the side flap while it was trying to open/close hence broke the piece since the pressure from the thread turning has no where else to go. The first step for the convertible top to open/close is for the clamshell to raise open. The actual sequence assuming the top was down is as follows (this is just my own amateur observation not the official steps from Porsche so take it with a grain of salt): The rear latch of the clamshell unlock The convertible top motor turn-on and slowly retracting the metal rod and while doing this it also unlock the 2 side latches The convertible top motor keep running and continue to raise the clamshell and stop when it raise completely The 2 side motors turn-on and pulling the side flaps down and stop when the flaps are completely down The hydraulic pump turn-on and push convertible top up all the way and forward The front latch engage and lock the top completely The convertible top motor turn-on again and push the metal rod which bring down the clamshell to close position and then lock the side latches The convertible top motor continue running and lock the rear latch then stop completely So to answer your question, you need to unlatch the 3 locks first. The key is on that Allen wrench screw, which from what you said I'm not sure if it is completely broken or just loose. If it is just loose (easy fix) just keep turn it to the left until it stops, nudge it by giving a little more force to "lock" it in place and then "slowly" turn it to the right (make sure it's not loosen the "lock") if all are good, your clamshell should slowly raising (or at least you should see it moving up a bit). In the worst scenario that the screw is also broken you might need to take it to the shop. While it might possible to do it yourself it might take a long time to do and difficult since there is almost no space to work on. Especially if you still have the rear canvas/carpet cover in place. -Andre

Thanks Rabit & Wizard for responding. No I haven't found any replacement part yet. It is summer here (I live in Northern California) so I have the top open all the time currently. I'm still searching before giving up and bite the bullet (getting a new motor). I even got another cheap motor from Audi (Bosch made) from EBay and open the housing since they look similar, hoping that the gear is the same (but no luck there). I'm currently out of town but when I'm back, I'll check and measure the gear (yeah I still got it) and hopefully qtcgears will have something similar. On side note, I didn't realize that there are response on my initial posting until today when I open the renntech.org forum. For whatever weird reason the notification email from renntech.org were automatically filtered by gmail and went to the "Promotions" (which I hardly open) instead of directly to inbox. -Andre

Well since by now I open/close this whole clam-shell manually and took apart the whole mechanism so many times, I kinda know the process by heart now. Assuming you already checked the obvious (i.e. no broken fuse, parking brake and light is on, trunk lid is close, light is off, battery is fully charge, etc.) When you press the button to open (assuming it's close) the latch near your overhead should unlatch. The next thing should happen you should hear a motor running on the back and the clam-shell to raise up. If you don't hear a motor running most likely either the motor busted or the micro-switch on the lid mechanism failed. You mention you attempt the manual procedure using the allen key, are you sure you turn it the correct way? This screw is tighten to the left and loosen to the right. If you turn the screw all the way to the left it, after so many turn it should stop and tighten. This is also lock the clam-shell. To open the clam-shell you need to make it "lock" and turn it to the right. It should unlatched the three hooks, 1 on the left side, 1 on the right side and and 1 on the back below the Porsche logo. Do it gently and the clam should start rising. When it's about 2" open you actually can pull the clam-shell by hand up and back. This whole process should work assuming that your screw is not actually broken. Once the clam-shell is completely raised up, if nothing else broken you should be able to press the button and open the top. Don't forget to lock/close the hydraulic nut (left of previously mention the screw if you facing it).

Hi guys, Newbie to the forum here. I have a 2002 996 C2 Cab new to me and been enjoying it since I got it 2 years ago. Mostly trouble free until two weeks ago when the cab top started to acting up and then quit all together. I had to do the emergency manual procedure, after checking all the obvious stuff (i.e. fuses, relays, micro-switches all tested and works). I started taking the mechanism apart, checked, cleaned and lubed everything, put it back together, run the calibration (Durametric), things start to work again wonderfully (or so I thought). The clam-shell lid started to hesitating and eventually got stuck halfway. I had to do the manual emergency operation again. Durametric gave a timeout error, the problem seems to be the clam-shell lid. Removed the motor and turned the mechanism manually it moves smoothly. Removed the lid motor by connecting it directly to the AC battery it's humming but the gear seems to turn hesitantly. So I took the motor apart and I found out that the plastic gear got chewed on one area (see attached pictures) where the worm gear rotating. I tried to rebuild the gear teeth by using JB Weld (and all kinds of epoxies brands and types), it's always working for a while and then same thing at the same area got chewed again. I guess it's not strong enough to hold the metal turning screw. My question now is, do I need to bite the bullet and get a new motor or do you guys have any recommendation if I can get this gear fix or custom made obviously within reasonable price (scratch that I just check with a CNC machine company it will cost roughly $300-$400). The price of a new motor is around 600 dollars at Sunset Porsche, a used one at eBay maybe around 300 - 400 dollars with the whole mechanism (which I don't need). Any suggestion is appreciate it. -Andre