Drive Cable Loose Fit on Transmission Drive Gear

[Mathelo]

Hi,

I’m new to this forum and could use some help. I searched these forums and found great help but not specific to my problem. Thanks go to all that post here.

I have a 2003 Boxster S. My top got stuck going up … the driver side clamshell was still in the full open position and the passenger side clamshell was up a few inches.

The problem appears to be the passenger side drive cable although the symptoms appear to be a bit different then what I’ve read here. On removing the cable from the motor, I found the inner drive cable sticking out 2” to 3”. I was able to pull it out further. At this point, I assumed the cable had snapped so I remove the transmission to have a closer look and also contemplating having to replace the cable at the transmission end.

On disassembly of the transmission, I found that the drive cable had come out of the transmission drive gear, or so it appeared. I could insert the cable back into the drive gear up to ¾” but it was a very loose fit. This doesn’t seem right. Do I need to replace the drive gear as well?

The inner drive cable is 42.75” long with 1.25” exposed for both ends combined. The drive cable seems okay.

What do you guys think?

Thanks!

Louis

[rcaudle]

Hi,

I’m new to this forum and could use some help. I searched these forums and found great help but not specific to my problem. Thanks go to all that post here.

I have a 2003 Boxster S. My top got stuck going up … the driver side clamshell was still in the full open position and the passenger side clamshell was up a few inches.

The problem appears to be the passenger side drive cable although the symptoms appear to be a bit different then what I’ve read here. On removing the cable from the motor, I found the inner drive cable sticking out 2” to 3”. I was able to pull it out further. At this point, I assumed the cable had snapped so I remove the transmission to have a closer look and also contemplating having to replace the cable at the transmission end.

On disassembly of the transmission, I found that the drive cable had come out of the transmission drive gear, or so it appeared. I could insert the cable back into the drive gear up to ¾” but it was a very loose fit. This doesn’t seem right. Do I need to replace the drive gear as well?

The inner drive cable is 42.75” long with 1.25” exposed for both ends combined. The drive cable seems okay.

What do you guys think?

Thanks!

Louis

Hi Louis - just curious if you ever found a solution to your problem as this is exactly the issue I ran into on my 2002 Boxster as well.

I followed the great forum posts on here and disconnected the driver side cable from the motor. I had my requisite 3/4" sticking out already, but pulled on the cable with my finger as suggested by Tool Pants/1schoir. The cable pulled out of the transmission with no troubles.

Upon inspecting the cable, there was no noticeable damage and both end were squared off.

I'm thinking perhaps that the worm gear somehow disconnected from the inner cable resulting in only one transmission moving (as I also encountered the clamshell opening crooked).

My plan is to try pushing the inner cable back into the worm gear and move the complete assembly with a drill.

I'll let you know how it goes.

Cheers,

Ryan

[rcaudle]

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Edited October 22, 2008 by rcaudle

[Tool Pants]

I have only worked on one new style transmission. I was able to pull the inner drive cable (square end) out of the worm gear with my fingers. On the old style you need tools to pull the inner cable out of th drive gear.

If you want to "glue" the cable so it will not accidently pull out you can clean everything with brake cleaner and use loctite.

[Peter Serbanica]

I would replace the cable.

[Peter Serbanica]

I reccomend replacing the cable.