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machster

996 Convertible top Tension Rope top Grommet

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I am trying to replace a broken grommet that holds the top portion of the Tension Rope on a 2003 911 cabrio. It has snapped at top of the Tension Rope. It appears to be removable and replaced with a new bolt. It also joins the roof frame at a pivot point. Please help@!

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Not sure if the tension rope for the 2003 is attached differently or not from the '99.  Mine is attached at the top to the roof frame via a small metal grommet-like attachment riveted to the roof hardware.  The rivet seems to be the weak link.  Replacement of the rivet on the "99 is a fairly straight forward process:

Tools:

Torx drivers - 15 and 20

Phillips head screwdriver

Pop rivet and tool

1.  Put the top in the service position;

2.  Remove the  torx screws holding the roof frame seal onto the most forward piece of roof on the side of the broken cable, and also remove the torx screws securing the front  roof frame seal retaining strip ( there is no need to remove the roof latch or either centering journal);

3.  Carefully loosen and remove the roof frame seal from the side and front side of the roof frame you are working on.  There is probably some water tight goop holding it on at the corner, and there is also a clip retaining it to the roof frame at the corner near the front corner forward-facing torx that had to come out.  It has been suggested that not all torx along the front retaining strip need to come out.  I removed all of them and completely removed the retaining strip since it seems pretty lightweight, and I did not want to run the risk of twisting it inadvertently. 

4.  Once the seal is out of the way, the phillips screws retaining the forward-most side frame piece can be accessed and removed. 

5.  At this point you can access the folded under roof material and carefully fold back the side and front material at the corner and work along the side.  There again may be some waterproof goop and/or two sided tape.  Be careful not to tear the roof fabric.

There is an "L" shaped piece of metal that runs along the side of the front frame piece and that is what the rivet holding the tension rope is attached to in my '99.  the roof is attached on the side to this piece via clips.  The entire piece is folded over with the roof material still attached to properly align the tension rope spring with the retainer with the replacement rivet all at the same time.  This would be a good time for an extra set of helper hands. 

6.  Pop in the new rivet, and reverse the entire process. 

Should not take more than 15-20 minutes.  Word of caution.  Have an extension magnet handy for when you drop the torx screw, or it gets stuck up in the rubber seal but not in line with the screw hole.  It's probably not a bad idea to cover with a towel any nearby body opens that a dropped screw might fall into.  Next time I'll try to take some pictures.

Edited by 99911

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