99 boxster top problem please help

[michaelmarkey]

A few months ago I bought a new window for my 99 porsche boxster. Finally this weekend I had the time but lost some of the directions, but I was able to get the top off. I sewed in the new window and then went to replace the top. Here's the mistakes I made:

I took the 10 mm bolt of the transmission arm and didn't mark it.

I broke one of the red ball joints and glued it back together.

I could figure out what a b pillar was so I don't know if that switch got put in the same place.

Here's what is happening now:

The top went all the way up and 2 inches from completely closing made a loud click click click noise. I put my hand back there and found it is the trans arms popping. The clam shell doesn't make any attempt to go up at all now. The top is completely closed and the window looks great however how do I get the clam shell up, top down, what most likely broke, and lastly since I didn't mark the arms that the 10 mm bolt connected how do I find the correct position.

Thanks,

Mike

[michaelmarkey]

do I just need to loosen the 10 mm bolts? Also, what does the switch do? Would this not working cause the problems I described.

Thanks,

Mike

[1schoir]

do I just need to loosen the 10 mm bolts? Also, what does the switch do? Would this not working cause the problems I described.

Thanks,

Mike

Mike:

The 10mm bolts (with the thick washer) are used to set the overall length of the pushrods. The length of the pushrods will determine how well the front edge of the convertible top will mate up with the top edge of the windshield frame.

If you look carefully at the slotted sides of the front part of the pushrods, you may be able to see tell-tale markings which will give you an indication of where the 10mm bolts were originally situated when tightened.

If not, just approximate the length by starting in the mid-range and work from there until the adjustment to the length of the pushrod yields the desired distance of the front edge of the convertible top to the top edge of the windshield frame.

Here is a photo of where the B-pillar microswitch is located (behind the carpet covered half round plastic trim piece just behind your left shoulder as you sit in the driver's seat):

The red arrow is pointing to the microswitch's small metal lever. If you operate that lever, it will reverse the direction of travel of the V-levers and your clamshell will close, etc... (Click on the photo to enlarge it).

The loud click click click noise is the sound of the half moon gear going past its last tooth and then being pulled sharply back by the force of the black hydraulic pushrods that operate on the clamshell.

Regards, Maurice.

Edited September 23, 2008 by 1schoir

[michaelmarkey]

Thanks a lot, I got the top and clamshell to move again. The ball joints are shot so I've already ordered the new ones off of ebay. I found the switch and found it's misplacement was a major part of the problem. I'm not very mechanical and just wanted to share my thanks with all of you for the great posts because if I can figure this out then anyone can.

Thanks again,

Mike

do I just need to loosen the 10 mm bolts? Also, what does the switch do? Would this not working cause the problems I described.

Thanks,

Mike

Mike:

The 10mm bolts (with the thick washer) are used to set the overall length of the pushrods. The length of the pushrods will determine how well the front edge of the convertible top will mate up with the top edge of the windshield frame.

If you look carefully at the slotted sides of the front part of the pushrods, you may be able to see tell-tale markings which will give you an indication of where the 10mm bolts were originally situated when tightened.

If not, just approximate the length by starting in the mid-range and work from there until the adjustment to the length of the pushrod yields the desired distance of the front edge of the convertible top to the top edge of the windshield frame.

Here is a photo of where the B-pillar microswitch is located (behind the carpet covered half round plastic trim piece just behind your left shoulder as you sit in the driver's seat):

The red arrow is pointing to the microswitch's small metal lever. If you operate that lever, it will reverse the direction of travel of the V-levers and your clamshell will close, etc... (Click on the photo to enlarge it).

The loud click click click noise is the sound of the half moon gear going past its last tooth and then being pulled sharply back by the force of the black hydraulic pushrods that operate on the clamshell.

Regards, Maurice.